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Univex Sportsman 700 EFI User's Manual

1. 00 32 MAINTENANCE AND LUBRICATION 64 100 Maintenance Record 68 Making Turns 53 Master Cylinder 35 N Noise Emission Control System 63 INDEX O Odometer eieaa a a a 42 Oil Change 0 4 72 Oil Filter Change 72 Oil levela re See ins Seis 71 OPERATION 46 62 Operator Safety 11 31 Override Switch 32 P Parking Brake 36 Parking on an Incline 62 Periodic Maintenance Chart 64 67 POLARIS PRODUCTS 107 Pre Ride Inspection 48 Premium 4 Synthetic Lubricant 70 PVT Drying 0 8 93 PVT System 08 92 93 R Radiator Coolant Level 76 Rear Gearcase Oil 75 Rear Spring 00 101 Reverse Override Switch 32 Rider Information Center 41 45 S Safe Riding Gear 10 SAFETY eid tes chet in cusses dhe 6 31 Safety Decals and Locations 6 9 Safety Training 11 Setting the Parking Brake 36 Side Panel Removal 81 Sidehilling 0 000 56 Signal words 00 12 Spark Arrestor 63 91 Spark Plugs 0 000 89 SPECIFICATIONS 108 109 116 S Starting the Engine 49 Steering Assembly 80 Storage oc See eee ee ee oes 97 100 Storage Tips
2. 00 98 99 SWItChES 6 eccecce ea eee cee ee 32 Stop Switch 0 0 00 0 008 32 Symbols erised rest pess ad eee 12 T TABLE OF CONTENTS 5 Tachometer 000 42 Taillight 0 0 0 00 ee ee 88 Throttle Cable Freeplay 102 Throttle Lever 0 5 cs oe ene oe 33 TIES SASF ben Salad de toes ERORE 82 Toe Alignment 80 Transmission Oil 2 73 Transporting the ATV 100 Traveling Downhill 57 Traveling Uphill 55 Trip Meter nisi Soe deesns Shee 6 42 TROUBLESHOOTING 103 106 Turning Around ona Hill 58 Vv VEHICLE IDENTIFICATION NUMBERS aooaa 4 Vehicle Immersion 90 WwW WARRANTY 110 114 WELCOME rete sede tik hoe ae 3 Wheel Installation 83 Wheel Nut Torque Specifications 83 Wheel Removal 82 Worklight 0 00000 88 Worklight Switch 32
3. 77 Corrosion 0000 100 Crankcase Emission Control System 63 D Diagnostic Mode 43 45 Driving in Reverse 61 Driving on Slippery Surfaces 54 Driving Over Obstacles 60 Driving Procedures 52 Driving Safely 52 62 Driving Through Water 59 E Electrical Switches 32 EMISSION CONTROL SYSTEMS 63 Engaging Front Gearcase 39 E Engine Cooling System 76 Engine Stop Switch 32 Equipment Modifications 15 Exhaust Emission Control System 63 F FEATURES 32 45 Filter Systems 0 84 Footwell Removal 81 Front Gearcase Oil 74 Front Wheel Hub Tightening 83 Buel Filtet escent cate avtcese Gsice 37 Fuel Safety 000 00e 46 Fuel Tank 00385 ice oe eee 37 G Gear Selector 00 38 H Handlebars 101 Hauling Cargo 50 51 Headlight Housing Replacement 87 Headlight Lamp Replacement 85 High Beam Adjustment 86 High Range 92 Hour Meter 0 08 42 l Instrument Cluster 40 45 K KLu erea a e E e 58 L Light Switches 0 34 Lights o seente see ce eee eu eee 85 88 Low Beam Adjustment 86 Low Range 4 92 Lower Headlamp 88 Lubrication Guide 69 M Main Switch
4. 1 Turn the key switch off and wait 10 seconds 2 Set the park brake and shift the transmission into neutral 3 Hold the mode reverse override button and turn the key switch on 4 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Battery voltage Screen 2 Tachometer Screen 3 AWD diagnostic This gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD Screen 4 Gear circuit diagnostic This screen displays the resistance value in ohms being read at the gear switch input of the gauge 43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5 Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance When your vehicle leaves the factory this feature is set at 50 hours You must enable the programmable service interval before it can be used Once the service interval mode is set with the hours when service is due the hours of actual engine operation are subtracted from the set hours until 0 is reached When the counter reaches 0 the wrench icon will flash quickly for 5 seconds each time the vehicle is starte
5. 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 4 amp 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 17 SAFETY Operator Safety 4 amp 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 4 amp 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
6. Inspect lubricate if necessary 69 Ensure free operation az nspect condition and pressure 82 109 Wheels fasteners nspect ensure fastener tightness nspect ensure tightness Ensure proper levels Ensure proper level kermi Ensure proper operation Ensure operation lt a Ensure proper operation 32 speci lear EE Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 85 tric grease when lamp is replaced Brake light tail lamp Check operation apply Polaris dielec 88 tric grease when lamp is replaced Riding gear Wear helmet goggles protective 0 clothing ie N i Coolant hoses if applicable Inspect for leaks ie N D 48 OPERATION Starting the Engine 4 amp WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Position the vehicle on a level surface with the transmission in PARK 2 Lock the park brake sit on the vehicle and turn the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 3 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the key allowing it to return to the ON position and wait five seconds Activate the starter for another five secon
7. FEATURES AND CONTROLS 4 amp WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever 1 The throttle lever Bey is spring loaded Engine speed returns to idle when the lever is 1 released This ATV is equipped with Polaris Electronic Ihrottle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 4 amp WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injury or death Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is properly installed to the ETC 33 FEATURES AND CONTROLS Light Switches The light s
8. Lift the adjusting knob up to remove it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod headlamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by gt turning the adjusting knob z 5 1 8 13 cm 87 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal Installation 1 Turn the back of the headlight harness 1 counterclockwise and pull the harness assembly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the headlamp Taillight Brakelight Worklight Lamp Replacement 1 Remove the harness ee connector 1 from the back of the light assembly 2 Turn the lamp 2 counterclockwise to remove it 3 Apply dielectric grease to the socket and install the new lamp 4 Reinstall the harness connector 5 Test the light for proper operation 88 MAINTENANCE AND LUBRICATION Spark Plugs e Use RC7YC spark plugs e Proper electrode gap is 035 90 mm e Spark plug torque is 18 ft Ibs 24 Nm CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Spark plug condition is indica
9. Sportsman Owner s Manual for M intenance and ates Qs POLARIS The Way Out Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age a vat AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER e Operate without proper training or instruction Operate on public roads A collision can occur with another vehicle e Operate at speeds too fast for your skills or the conditions e Use ALCOHOL or DRUGS before or while operating this vehicle e Carry Passengers ALWAYS e Avoid paved surfaces which may adversely affect handling and control e Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns e Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS Part No 9919426 Rev 02 c gt PeELARIS PRINTED IN THE USA The Way Out AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has be
10. The recommended toe alignment is 1 8 to 1 4 toe out 1 Set the handlebars in a straight ahead position Oe al eo K Bad ZOO Gag ee NOTE The steering frog can be used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts If loose nuts and bolts are found see your Polaris dealer for service before operating the vehicle CP g og oO ata a 1 i Sy MTT 80 MAINTENANCE AND LUBRICATION Side Panel Removal 1 pA Remove the seat Grasp the rear of the side panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet
11. Whenever traveling uphill follow these precautions Always travel straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Transfer your weight forward Proceed at a steady rate of speed and throttle opening Oy Uy Ge BO Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 4 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 55 OPERATION Driving Safely Sidehilling 4 WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be the most dangerous type of driving encountered and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quic
12. Operator Safety 4 amp WARNING 16 POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris Operators should regularly practice the skills learned in the course and the operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV SAFETY Operator Safety amp 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
13. around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 58 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 25 SAFETY Operator Safety 4 amp WARNING 26 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 brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 58 SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overt
14. detergents or high pressure washers Some detergents deteriorate rubber parts Use dish soap type cleaners only High pressure washers may force water past seals Stabilize the Fuel Fill the fuel tank Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon clean will also reduce the possibility of bacterial growth in the fuel system Allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank Oil and Filter Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Fluid Levels Inspect the following fluid levels and change if necessary front and rear gearcases transmission and brake fluid change every two years or as required if fluid looks dark or contaminated 98 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean following the instructions on the can Run the engine for several minutes so the Carbon Clean reaches the injectors Turn the engine off 2 Remove the spark plugs and add 2 3 tablespoons of Premium 4 Synthetic 0W40 engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil NOTE Do this carefully If
15. heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles 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 77 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting The following checks are recommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 4 amp WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 1 Always keep brake fluid at an adequate level see page 35 4 amp WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill NOTE Unde
16. 3764 to find out about the training courses nearest you e Never allow anyone under 16 years of age to operate this ATV e Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safe ty training course e Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets e Never operate an ATV on a public street road or highway including a dirt or gravel road e 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 e Never consume alcohol or drugs before or while operating an ATV e Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience e Never attempt wheelies jumps or other stunts e Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual e Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation e Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions e Never operate on excessively rough slippery or loose terrain e Always follow proper turning pr
17. 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1200 LBS 545 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks With dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information 7172748 NEVER ride as a passenger Passengers can cause a loss of control resuiting in SEVERE INJURY or DEATH 7172566 ATTENTION e Operation of this vehicle without the air filter element will severely damage the engine e Clean pre filter element often more frequent cleaning required in dusty conditions Do not operate vehicle without pre filter 7172921 SAFETY Safety Decals and Locations AWARNING AWARNING Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death Operating this ATV if you are under the age of 16 increases y
18. Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12 8 VDC Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Solution times for 5 seconds each then start Recharge battery to 12 8 VDC Mechanical failure Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs 104 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Engine Runs Irregularly Stalls or Misfires Possible Weak Spark Cause Solution Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent
19. Pull the panel downward and rearward to remove it from the ATV Reinstall the side panel by reversing the removal procedure Footwell Removal 1 2 3 Remove the four screws 1 on the bottom of the footwell Use a flat screwdriver or sidecutters to remove the plastic rivets 2 securing the footwell to the fenders Remove the footwell 81 MAINTENANCE AND LUBRICATION 4 amp 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 cm or less Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less See illustration 1 8 3 cm Wheel Removal 1 Stop the engine place the transmission in park and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 4 Remove the wheel nuts and remove the wheel 82 MAINTENANCE AND LUBRICATION Wheel Installation 4 amp WARNING Improperly installed wheels can adversely affect tire wear and vehicle
20. handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in park and lock the parking brake 2 Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Location Torque Front Wheel Nuts 27 ft Ibs 37 Nm Rear Wheel Nuts 27 ft Ibs 37 Nm Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized Polaris dealer 83 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1 84 Remove the seat release the air box cover clips and remove the air box cover Loosen the clamp and remove the filter Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water then rinse and let dry Reinstall the pre filter over the main filter Replace the main filter if needed Reinstall the filter into the air box and tighten the clamp Do not over tighten t
21. immersed or is operated in water that exceeds the footrest level take it to your dealer for service before starting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 90 Have the vehicle serviced by your dealer at the first opportunity 59 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 4 amp 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 60 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Always avoid backing downhill 2 Back slowly 3 When in reverse apply the brakes lightly for stopping 4 Avoid turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 4 amp WARNING Failure to use caution when operating in reve
22. line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Possible Rich Fuel Mixture Cause Solution Fuel is very high octane Replace with lower octane fuel 105 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheat
23. the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 93 MAINTENANCE AND LUBRICATION Battery 4 amp WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal 1 Disconnect the battery hold down strap 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable last 4 Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 95 before installing the battery 1 Ensure that the battery is fully charged Set the battery in the battery holder Connect and tighten the red positive cable first Connect and tighten the black negative cable last Attach the hold down strap Verify that cables are properly routed ON A 94 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and
24. tires specified for your ATV and always maintain proper tire pressure e Never modify an ATV through improper installation or use of acces sories e Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 15 SAFETY
25. 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 110 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been altered structurally modified neglected improperly maintained used for racing or used for purposes other than for which it was manufactured or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts In addition this warranty does not cover physical damage to paint or finish stress cracks tearing or puncturing of upholstery material corrosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLA
26. you miss the plug holes oil will drain from the spark plug cavities into the hole at the front of the cylinder head and appear to be an oil leak 3 Reinstall the spark plugs Torque to 18 ft Ibs 24 Nm 4 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 5 Turn the engine over several times Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If Polaris fuel system additive is not used fuel tank fuel lines and injectors should be completely drained of gasoline Inspect and Lubricate Inspect all cables and lubricate Follow lubrication guidelines in the Maintenance Section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease Battery Maintenance Remove the battery and recharge it as outlined on page 95 Store the battery in a cool dry place Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilated and cover the machine with a genuine Polaris ATV cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 99 MAI
27. 66 Maintain the oil level even with the bottom of the fill hole threads 1 We recommend the use of Polaris Premium Demand Drive Hub Fluid Use of other oils may result in improper operation of components See page 107 for the part numbers of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug 2 and view the oil level 3 Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Oil Change 1 Position the vehicle on a level surface and remove the fill plug 2 Place a drain pan beneath the gearcase remove the gearcase drain plug 3 located on the bottom right hand side and drain the oil 3 Clean and reinstall the drain plug Torque to 11 ft lbs 15 Nm 4 Add 5 ounces 150 ml of Polaris Premium Demand Drive Hub Fluid 5 Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm 6 Check for leaks 74 MAINTENANCE AND LUBRICATION Rear Gearcase Oil The rear gearcase fill plug 1 is located on the rear of the gearcase Always check and change the rear gearcase oil at the intervals outlined in the J Periodic Maintenance Chart 2 beginning on page 64 Maintain the rear gearcase oil level 2 even with the bottom of the fill hole We recommend the use of Polaris ATV Angle Drive Fluid or GL5 80 90 weight gear lube See page 107 for the part numbe
28. 68KG 7170509 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding ATV riding requires special protective clothing for comfort and to reduce the chance of injury 1 Helmet Your helmet is the most important piece of protective gear for safe riding A helmet can prevent a severe head injury Select an approved helmet that meets or exceeds your state s safety standards and bears either the Department of Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4 Boots The best footwear is a pair of strong over the calf boots with heels like moto cross boots 5 Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a jersey with shoulder pads provide the best protection 10 SAFETY Operator Safety 4 amp WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles su
29. E FRONT HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS Vehicle should never exceed 10 mph 16 kph while towing a load on a level grass surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 51 OPERATION Driving Safely Driving Procedures 52 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up then shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same le
30. ERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR 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 1997 2000 7172560 4 amp WARNING Never operate this ATV on HILLS steeper than 25 degrees Lae To prevent flipover on hilly terrain when going up or down 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 e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle When this ATV is not in operation or unattended place shift in the park position 7172561 SAFETY Safety Decals and Locations AWARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR
31. H High Range 3 L Low Range N Neutral R Reverse P Park 2 2 AWD Indicator This indicator illuminates when the electrical portion of the AWD system is enabled 3 Engine Hour Display Indicator 1 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged A low battery warning may also occur under normal operation if the machine is at idle and high electrical load lights cooling fan accessories is applied Driving at a higher RPM or connecting a battery charger will usually clear the warning 6 Odometer Tachometer Tripmeter Hour Meter 7 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator This indicator serves two purposes The word HOT displays if the engine overheats It also appears if an EFI related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator a 41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes Mode 1 Odometer Mode 2 Tripmeter Mode 3 Total Service Hours Mode 4 Tachometer The reverse o
32. H 12M 1000 1600 Inspect clean replace worn and driven parts Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings 6M Brake fluid 200 H 2000 3200 Change every two years Fuel filter 200 H 24M 2000 3200 Check for leaks around lines Replace every 2 years more often under extreme conditions mese usta needed U U UOU Toe adjustment Inspect periodically adjust when parts are replaced Headightam fastas OU gt Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 67 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Servicing Servicing Interval Date Dealer Performed or Person 68 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Items not listed in the chart should be lubricated at the General Lubrication interval Lubrication Guide Key p gt More often under severe use such as wet or dusty conditions Polaris Premium All Season Grease or grease conforming to NLGI No 2 such as Conoco Superlube M or Mobilegrease Special e Use Polaris Premium U Joint Lube every 500 miles before long periods of storage or after pressure washing or submerging ic Se i S
33. NING 20 POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation SAFETY Operator Safety 4 amp 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 4 amp WARNING POTENTIAL HAZARD Failure to use extra caution when opera
34. NTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion preserve wheel life and ensure a like new appearance for many years 1 Wash chrome rims frequently Use a mild detergent to remove any salt dirt mud or grime Never use abrasive cleaners on plated or painted surfaces 2 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 3 Routinely and liberally apply a weather resistant wax to each polished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions 4 Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above Transporting the ATV Follow these procedures when transporting the vehicle 1 Turn off the engine and remove the key to prevent loss during transporting 2 Place the transmission in PARK and lock the parking brake 3 Turn the fuel valve off and be sure the fuel cap oil cap and seat are installed securely 4 Always
35. ON Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic Oil or another OW 40 API certified SH oil Never substitute or mix oil brands 1 Fill the fuel tank with gasoline See page 37 Check the engine oil level on the dipstick See page 71 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month 47 OPERATION Pre Ride Inspection 4 amp 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 Brake system lever travel Page Ensure proper operation Ensure proper level Ensure proper operation Inspect lubricate if necessary 69
36. RIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties so the above limitations or exclusions may not apply to you if inconsistent with controlling state law 111 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any add
37. ROLS Engine Electrical Switches 4 amp WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch 1 This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on This switch is also used to toggle through the different modes of the rider information center See page 40 Engine Stop Switch 2 The engine will not start or run when the switch is in the OFF RUN OFF OFF position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency gt NOTE The cooling fan motor does not shut off when the stop switch is used to stop the engine Turn off the main ignition switch to turn off the cooling fan motor Main Switch 3 To start the engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts NOTE Both the main switch and the emergency engine stop switch will shut off all electrical power to the vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position Worklight Switch 4 32
38. Watercraft e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your Polaris vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period We also take great pride in our Parts Apparel and Accessories PAA products available through our online store at www purepolaris com Have your accessories and clothing delivered right to your door POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc VEHICLE IDENTIFICATION NUMBERS Record your ATV s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys so if both keys a
39. White EBS 6000 12000 PN 5631214 PN 7041157 PN 3234199 PN 3234208 EBS models require no helix spring adjustment 109 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferrable to another consumer during the 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 THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set
40. al type washing mitten cleaning the upper body first and the lower parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement CAUTION High water pressure may damage ATV components Polaris recommends washing the ATV by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage plastic surfaces Do not allow these types of products to come into contact with the ATV If a high pressure water system is used exercise extreme caution to avoid damaging wheel bearings radiator transmission seals body panels brakes and warning labels Grease all zerk fittings immediately after washing and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system Waxing the ATV Your ATV can be waxed with any non abrasive automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish 97 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime Don t use harsh
41. aler for adjustment Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of the adjuster 1 2 3 102 TROUBLESHOOTING Drive Belt and Cover Problems Driving the ATV onto a Shift transmission to low range during loading of the ATV pickup or tall trailer in to prevent belt burning high range Starting out going up a When starting out on an incline use low range or dis steep incline mount the ATV after first applying the park brake and perform the K turn as described on page 58 Driving at low RPM or Drive at a higher speed or use low range more frequently low ground speed at The use of low range is highly recommended for cooler approximately 3 7 MPH PVT operating temperatures and longer component life Insufficient warm up of Warm the engine at least 5 minutes With the transmission ATVs exposed to low am in park advance the throttle to about 1 8 throttle in short bient temperatures bursts 5 to 7 times The belt will become more flexible and prevent belt burning Slow and easy clutch en Use the throttle quickly and eff
42. aning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds 4 amp WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 53 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 2 54 Slow down when entering slippery areas Engage AWD before wheels begin to lose traction Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution OPERATION Driving Safely Traveling Uphill 25 Maximum
43. ased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Vehicles registered to Government officials or mili tary personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 763 417 8650 Canada 1 204 925 7100 114 A ACCESSOTIES Se ee eee eee ee 64 ADJUSTMENTS 101 102 Age Restrictions 11 Air Filter Service 84 All Wheel Drive 39 Automatic Transmission 38 Auxiliary Brake 79 AWD eaa ee A eters Gis N 39 B Battery ci sain Stal te ne Soe 94 96 Battery Charging 95 96 Battery Installation 94 Battery Removal 94 Battery Storage 00 95 Belt Lifes ccna yie ee chee sey 38 Brake Fluid 35 37 Brake Lever 000 34 Brake Auxiliary 37 Brakelight 00 88 Brakes eener iea 78 79 Break In Period nananana 47 Cc Camber and Caster 101 Chrome Wheel Care 100 Cleaning osu eee onisu ba een 97 100 Clutching Chart 109 Cold Weather Operation 49 CONTROLS 32 45 Coolant Level 0 77 Cooling System 77 Cooling System Operation
44. at the intervals outlined in the Periodic Maintenance Chart beginning on page 64 Always change the oil filter whenever changing oil 1 2 3 4 Position the vehicle on a level surface Run the engine for two to three minutes until warm Stop the engine Clean the area around the drain plug Place a drain pan beneath engine crankcase and remove the drain plug Allow the oil to drain completely Replace the sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be 10 11 12 13 14 15 16 72 clean and free of burrs nicks or scratches Reinstall the drain plug and torque to 20 ft lbs 27 Nm Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove Using a clean dry cloth clean the filter sealing surface on the crankcase Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition Install the new filter and turn by hand until the filter gasket contacts the sealing surface then turn and additional 1 2 turn Remove the dipstick and fill the sump with two quarts 1 9 1 of recommended oil Place the gear selector in park and set the parking brake Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dip
45. ch as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age Know Your Vehicle As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV from a party other than a Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is design
46. d as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the button down until the count turns over to 0 You can then reset the number If the service interval is enabled on your ATV and you wish to turn it off toggle to the service interval mode Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center Screen 6 Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles The current display mode will be shown as KM or MP To change hold in the mode button until the letters flash then press and release the button once When the display stops flashing the mode has been set 44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only Please see your Polaris dealer for all major repairs To download blink codes failure cod
47. ds if necessary Repeat this procedure until the engine starts CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle Cold Weather Operation If the ATV is used year round check the oil level frequently A rising oil level could indicate the accumulation of 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 Water accumulation increases as outside temperature decreases See your Polaris dealer for engine heater kits which provide quicker warm ups and easier starting in colder weather 49 OPERATION Hauling Cargo 2 3 Your ATV has been designed to carry or tow a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Belt Life Use low forward gear when hauling or towing heavy cargo to extend belt life 50 OPERATION Hauling Cargo 4 amp WARNING Ha
48. e Frame fasteners o e g Air filter pre filter HRR Inspect clean often Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp worklight dielectric grease if replacing Air filter Weekly Inspect replace as needed main element Recoil housing Weekly Drain water as needed check often if operating in wet conditions Brake pad wear Monthly 100 160 Inspect periodically 7 Monthly 200 320 Check terminals clean test Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped Rear gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km Transmission oil 25H Monthly 250 400 Inspect level change yearly Engine breather 25H Monthly 250 400 Inspect clean if needed filter if equipped General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50 H 500 800 Drain bowl periodically and bowl prior to storage Throttle Cable 50H 500 800 Inspect adjust l
49. e Engine Oil Polaris Premium 4 Add to proper level on dipstick Synthetic OW40 Brake Fluid DOT 3 Only Maintain level between fill lines See page 35 Transmission Oil Polaris AGL Synthetic See page 73 Gearcase Lube Front Gearcase Oil Premium Demand See page 74 Drive Hub Fluid Rear Gearcase Oil ATV Angle Drive Fluid See page 75 or GL5 80 90 weight gear lube Front Prop Shaft Yoke Grease Grease fittings 3 pumps maximum Fig 1 Ball Joint Fig 2 p Grease Locate fitting on back side of struts and grease with grease gun 69 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 107 for the part numbers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F 40 to 49 C Its exceptional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is
50. e traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country be fore 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 cov erage You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 113 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 pur ch
51. ectively for efficient enga gagement gement Towing pushing at low Use low range only RPM low ground speed Utility use plowing snow Use low range only dirt etc Stuck in mud or snow Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large ob Shift the transmission to low range and carefully use fast jects from a stopped posi brief aggressive throttle application to engage clutch tion WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water Shift the transmission to park Using the throttle vary the or snow ingestion into the engine RPM from idle to full throttle Repeat several PVT system times as required During this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking occurs Clutch malfunction Contact your Polaris dealer for inspection of clutch com ponents Poor engine performance Replace old or off season fuel with fresh fuel Check for fouled plugs or foreign material in gas tank fuel lines or fuel filter See your dealer for service 103 TROUBLESHOOTING Contact your Polaris dealer for service if you re unable to identify solutions using the following charts Engine Doesn t Turn Over Possible
52. ed engine Clean radiator screen and core Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency 106 POLARIS PRODUCTS Part No Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 2873602 2873603 2871653 2872275 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871557 2871312 2871329 2872073 2872348 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 107 SPECIFICATIONS SPORTSMAN 700 EFI tongue weight not to exceed 200 lbs 91 kg Displacement 683 Ignition System ECU Based on EU Directive 76 432 EC 108 SPECIFICATIONS SPORTSMAN 700 EFI Shift Type Side Lever H L N R P Gear Reduction Low 7 49 1 Single Control Hydraulic Disc Headlight 1 Single Beam on Handlebar 50 watt a E Clutching Chart Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 20 56 Blue Green White EBS Feet 0 6000 PN 5631215 PN 7041157 PN 3234199 PN 3234208 1800 3700 20 54 Blue Green
53. ed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals 11 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 A A A The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle IMPORTANT IMPORTANT will alert you to important information or instructions NOTE A note will alert you to key information or instructions 12 SAFETY Operator Safety 4 amp 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 e Read this manual and all labels carefully and follow the operating procedures described e Never operate an ATV without proper instruction Take a training course Beginners should receive training from a certified instructor Contact an authorized Polaris ATV dealer or call Polaris at 1 800 342
54. eel Drive system which is activated by the AWD switch 1 on the right handlebar When the switch is off the ATV is in two wheel drive at all times When the switch is on the ATV is in AWD and the AWD indicator light in the instrument cluster will be on When in AWD the front gearcase will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the front gearcase will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 32 There is no limit to the length of time the vehicle may remain in AWD Engaging the Front Gearcase The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the front gearcase is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 39 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an inst
55. en removed please call 1 800 342 3764 for assistance oS Ae PesLARIS For 50 years we ve been helping Polaris customers find The Way Out It s been a fun ride But then after all these years That s what we re all about Find out more about our exciting once in a lifetime 50th Anniversary celebration Go to www polarisindustries com and look for the 50th Anniversary link This is a ride you don t want to miss POLARIS The Way Out F En i i E a axe i ps Copyright 2004 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2005 Sportsman 700 EFI Owner s Manual P N 9919426 2 WELCOME Thank you for purchasing a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products Polaris Recreational Vehicles e Snowmobiles e All terrain vehicles ATVs e
56. es from the EFI module 1 Place the transmission in PARK turn the engine off and turn the key switch to the ON position 2 Turn the key switch off and on three times in less than five seconds then leave the switch on Any blink code numbers stored in the EFI module will display one at a time in the alphanumeric display The number 61 and the word END will display after all codes have been transmitted Blink Failure Description Blink Failure Description Code Code at No RPM Signal Engine Temp Lamp Open Load 21 Loss of Synchronization 54 Engine Temp Lamp Short Circuit to Ground 45 Barometric Pressure Sensor 54 Engine Temp Lamp Short Circuit Circuit Low Input to Battery 46 Barometric Pressure Sensor 55 Diag Lamp Open Load Circuit High Input 22 TPS Open or Short Circuit to 55 Diag Lamp Short Circuit to Ground Ground TPS Short Circuit to Battery Diag Lamp Short Circuit to Battery 23 RAM Error Defective RAM Error Defective ECU 56 Pump Relay Open Load Relay Open Load e Temp Sensor Circuit ee ee Short Circuit to Short to Ground Ground 42 Engine Temp Sensor Circuit 56 Pump Relay Short Circuit to Open or Short to Battery Battery 51 Injector 1 Open Load 41 Intake Air Temp Sensor Open or Short Circuit to Sensor Voltage Injector 1 Short Circuit to Ground Intake Air Temp Sensor Short Circuit to Ground 51 Injector 1 Short Circuit to Battery 1 Short Circuit to Bat
57. go improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer 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 SAFETY Operator Safety 4 amp 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 4 WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Exposure to the hot components could result in a fire Always keep combustible materials away from the exhaust system 31 FEATURES AND CONT
58. hart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer Maintenance Chart Key p Perform these procedures more frequently for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 4 amp WARNING Improperly performing the procedures marked with a m could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 64 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first Maintenance Interval whichever comes first Calendar Miles Km Pre Ride Pe Make adjustments as need Farner a A chs pe p e CEA CE Pern Pre Ride Whestafesteners Pre Rid
59. he clamp as filter damage could occur Reinstall the air box cover and the seat DAN NY ws ns eiD gt Te Kitr MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp 4 WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 85 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adju
60. 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 18 SAFETY Operator Safety 4 amp 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 4 amp 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 4 amp WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving 19 SAFETY Operator Safety 4 amp WAR
61. instructions for recharging When using a constant current charger use the following guidelines for recharging 4 amp WARNING An overheated battery may explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging 95 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE Always verify battery condition before and 1 2 hours after the end of charging State of Voltage Charge Time Charge Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts None check at None required 3 mos from date of manufacture 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 At least 20 hours desulfating charger 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 96 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 107 for the part numbers of Polaris products Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components With a few precautions your ATV can be cleaned much like an automobile Washing the ATV The best and safest way to clean your ATV is with a garden hose and a pail of mild soap and water Use a profession
62. irectly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Fuel Filter The in line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris Do not attempt to clean the fuel filter 37 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector 1 is located on the right side of the vehicle H High Gear L Low Gear N Neutral R Reverse P Park To shift into HIGH or PARK you must first apply the auxiliary brake to activate the high park lock out mechanism When shifting out of HIGH or PARK it s not necessary to apply the brake UV Zr I Whenever the ATV is left unattended always place the transmission in park and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Apply the auxiliary brake if shifting into HIGH or PARK Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 38 FEATURES AND CONTROLS All Wheel Drive AWD System Polaris 4 wheel drive ATVs are equipped with a unique Polaris exclusive On Demand All Wh
63. itional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty 112 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any ques tions This policy does not apply to vehicles registered to government offi cials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or ar
64. ke the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 2 Move the ATV to dry land or at the very least to water below the footrests Check the air box for any water and dry it if it s wet NOTE Filter replacement is required if water is present NM Pw Remove the spark plugs Turn the engine over several times using the electric start Dry the spark plugs and reinstall or replace with new plugs Attempt to start the engine If necessary repeat the drying procedure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure 90 on page 93 for drying out the PVT MAINTENANCE AND LUBRICATION Spark Arrestor 4 amp WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inc
65. kly turn the front wheel downhill if possible or dismount on the uphill side immediately 56 OPERATION Driving Safely Traveling Downhill 4 WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death When traveling downhill follow these precautions 1 Transfer your weight to the rear 2 Drive straight down the hill 3 Slow down Squeeze the brake lever gradually WARNING Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control Before operating your ATV learn how the auxiliary brake works in case you lose your normal service brakes 57 OPERATION Driving Safely Turning Around on a Hill 4 WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when you must turn around while climbing a hill is the K turn 1 Stop and lock the parking brake while keeping body weight uphill 2 Leave the transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars ful
66. l left 5 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground 58 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests 1 Follow these procedures when operating through water T 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 64 The following areas need special attention engine oil transmission oil front and rear gearcases and all grease fittings 4 amp 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
67. l 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 Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid operating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes 14 SAFETY Operator Safety e 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 e Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles e Always use the size and type of
68. ld be checked before each ride The fluid level can be seen through an indicator window 2 on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid needs to be added the eye will be clear f UE NOTE When checking the fluid level the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 107 for the part numbers of Polaris products 4 amp WARNING After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury 35 FEATURES AND CONTROLS Parking Brake 4 amp WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Setting the Parking Brake 1 Place the transmission in park 2 Squeeze and release the brake lever 1 two or three times then squeeze and hold 3 Push the park brake lock 2 forward to engage the brake Release the brake lever 4 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The pa
69. lined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug 1 from the bottom of the muffler Place the transmission in PARK and start the engine Purge carbon from the system by momentarily revving the engine several times If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in PARK and repeat steps 3 and 4 until no more particles are expelled when the engine is revved Stop the engine and allow the arrestor to cool Reinstall the arrestor plug and remove the outlet cover or plug 91 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of centrifugal force decreases reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the ope
70. ng system has been drained for maintenance or repair replace the coolant If the recovery bottle has run dry the level in the radiator should be inspected Add coolant as needed 4 amp WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 To access the radiator pressure cap open the front box lid and pull open the access door 2 Remove the pressure cap 1 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap secure the access door and close the box NOTE Use of anon standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 76 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle 1 is located on the left side of the machine To access the recovery bottle remove the left side panel XI as outlined on page 81 ss Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool Add coolant as needed Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding
71. not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic oil or another OW 40 API certified SH oil Never substitute or mix oil brands 70 MAINTENANCE AND LUBRICATION Oil Level The oil dipstick and fill tube 1 is located on the engine and is accessible on the left side of the ATV 1 2 NOTE Due to the dipstick entry 6 Position the ATV on a level surface Start the engine and let it idle for 20 30 seconds then stop the engine Lift the lever lock 2 to remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely but do not lock it The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 2 SAFE ADR 8 07 Remove the dipstick oe A 3 and check the oil level Maintain the oil level in the safe range 3 Do not overfill angle into the crankcase the oil level will read higher on the bottom side of the dipstick Always read the level on the upper surface 4 of the dipstick After reinstalling the dipstick be sure to seat the lever lock 71 MAINTENANCE AND LUBRICATION Oil and Filter Change 4 amp CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to come into contact with skin Always change the oil and filter
72. ocedures as described in this manu al Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds 13 SAFETY Operator Safety Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate 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 ter rain carefully before ascending a hill Never climb hills with exces sively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight backward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when pos sible Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stal
73. or be installed and functional when the vehicle is operated on public lands Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI components are set at the factory for optimal performance and are not adjustable Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 63 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights See your Polaris dealer Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following c
74. our chance of severe injury or death N ST E P NEVER operate this ATV if you are 7172563 under age 16 7172559 AWARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Max Rack Loads Front 100 Ibs 45 kg Rear 200 Ibs 91 kg 7172749 SAFETY Safety Decals and Locations 4 WARNING ALL WHEEL MANUFACTURED Pushing reverse DRIVE BY POLARIS IND INC override button SWITCH DATE may cause sudden increases VIN in power and Do not push switch to lint engage AWD if the rear traction if too Gin THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT much throttle is wheels are spinning INTENDED FOR USE ON PUBLIC ROADS applied Loss of This may cause severe control or forward drive shaft and clutch CE V HICULE EST UN V HICULE TOUT TERRAIN QUI N EST flipover may damage PAS DESTIN TRE UTILIS SUR LES CHEMINS PUBLICS result especially See your Owner s PATENT NOTICE Mid by Al Terrain Vehicle Division Polaris Industries Inc und f the i AWD See Manual following patents Other patents pending U S Patents wner s Manual 4697665 5036939 5975624 7172564 6016943 6092877 6149540 7079780 6224134 6270106 6340186 378080 0389440 0400143 Canadian Certification Decal 7171492 TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS
75. r 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 ciap agm operation Use Polaris DOT 3 brake fluid Do not overfill 78 MAINTENANCE AND LUBRICATION Brakes 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc NOTE Replace brake pads when they are worn to 3 64 1 cm 3 64 1 cm Auxiliary Brake The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system requires no adjustment NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system 79 MAINTENANCE AND LUBRICATION Toe Alignment 4 amp WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle
76. ration of the PVT especially at speeds less than 7 MPH 11 KPH due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 KPH in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc When To Use Low Range vs High Range Following is a guideline for when to use low range and high range Low Range e When basic operation is at speeds less than 7 MPH 11 KPH e For heavy pulling e When operating in rough terrain swamps mountains etc at low ground speeds High Range e When basic operation is at speeds greater than 7 MPH 11 KPH e When operating at high ground speeds 92 MAINTENANCE AND LUBRICATION PVT System amp WARNING Failure to comply with the instructions in this warning can result in severe inju
77. re lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number 2 Key Number 3 TABLE OF CONTENTS WELCOME e OA Si ot crab E E ei dort Uk cae 3 VEHICLE IDENTIFICATION NUMBERS 4 SAFETY vii eae haw was Rie tees eee 6 FEATURES AND CONTROLS 0055 32 OPERATION saz cents ietitd cama sailed EET 46 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 ADJUSTMENTS sieste nih atetule tS E E a eh R oes 101 TROUBLESHOOTING ace dei eer tennveer ede cue ees 103 POLARIS PRODUCTS i iiwiwctewaiwne rome anne on ne 107 SPEGIFIGATIONS x4 e0 cs net aen e e ed ae es 108 WARRANTY ee ec t kote art tel ele ni eh A sata tala 110 INDEX 2s pstolient ast eta eter EN AE 115 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal 4 WARNING Improper ATV use can result in SEVERE INJURY or DEATH DOG ALWAYS USE NEVER USE NEVER CARRY NEVER USE AN APPROVED ON PUBLIC PASSENG
78. rking brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling e 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 36 FEATURES AND CONTROLS Auxiliary Brake 4 amp WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death Your Polaris ATV has an auxiliary brake 1 for added safety It s located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the auxiliary brake Maintain the fluid level between the maximum and minimum marks Fuel Tank The fuel tank filler cap 1 is located d
79. rs of Polaris products Oil Check 1 Position the ATV on a level surface 2 Remove the fill plug and view the oil level through the fill plug hole 3 Add the recommended gearcase oil as needed 4 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Oil Change 1 Place a drain pan beneath the drain and remove the drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft Ibs 19 Nm 3 Remove the fill plug and add 5 ounces 150 ml of the recommended gearcase oil 4 Inspect the oil level which should be maintained level with the bottom of the fill plug hole 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 6 Check for leaks 75 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 107 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Any time the cooli
80. rse 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 4 amp 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 in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals amp WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 29 SAFETY Operator Safety 4 amp WARNING 30 POTENTIAL HAZARD Overloading the ATV or carrying towing car
81. rse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 61 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in park 3 Set the parking brake 4 Always block the rear wheels on the downhill side as shown 62 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with state and local noise level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrest
82. rument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 32 for additional information P amp SLARIS 1 Rider Information Center Speedometer needle in addition to showing vehicle speed the needle flashes when a warning condition exists 3 Speedometer CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellants and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to come into contact with the lens Immediately clean off any gasoline that splashes on the instrument cluster 40 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All segments will light up for 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator As the shift lever is moved this indicates the gear the transmission is in 4 5 6
83. ry or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before operating 1 2 Remove the drain plug and allow the water to drain Replace the drain plug Start the engine and shift the transmission into park Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the transmission to the lowest available range Test for belt slippage If
84. s for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other side of the hill 23 SAFETY Operator Safety 4 amp WARNING 24 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 57 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 4 amp WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV
85. stick Dispose of used filter and oil properly MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the Lae 7 transmission oil at the intervals outlined EE j I ie in the Periodic Maintenance Chart pel beginning on page 64 Maintain the K aire transmission oil level at the bottom of the fill plug hole 1 We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant See page 107 for the part numbers of Polaris products The transmission oil fill plug 2 is located on the right side of the ATV behind the footwell The transmission drain plug 3 is located on the bottom left hand side of the gearcase Oil Check 1 Remove the footwell see page 81 2 Remove the fill plug and check the oil level 3 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm 4 Reinstall the footwell Oil Change 1 Remove the footwell see page 81 2 Remove the drain plug and drain the oil into a drain pan Dispose of properly 3 Clean and reinstall the drain plug Torque to 14 ft Ibs 19 Nm 4 Remove the fill plug and add 15 oz 450 ml of the recommended transmission oil 5 Reinstall the fill plug Torque to 14 ft Ibs 19 Nm Check for leaks 7 Reinstall the footwell a 73 MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page
86. stment 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a 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 two inches 5 1 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw 2 located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw 86 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1 2 3 mn CS RPNDH NOTE The distance from the Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs
87. store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Battery charge can be maintained by using a Polaris Battery Tender charger PN 2871076 or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installation of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until thebattery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s
88. tery ee Injector 2 Open Load Injector 2 Short Circuit to Ground Injector 2 Short Circuit to Battery 45 OPERATION Fuel Safety WARNING 46 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 WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas OPERATION Break In Period The break in period for your new Polaris ATV is defined as the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTI
89. tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 100 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Handlebars amp 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 The handlebars can be adjusted for rider preference 1 Locate handlebar bolts 1 by removing the upper headlight pod 2 Loosen the four bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 will remain at the rear of the clamp blocks 101 ADJUSTMENTS Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle speed is not satisfactory please see your Polaris de
90. ting 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 21 SAFETY Operator Safety 4 amp WARNING 22 POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 Practice on smaller hills before attempting large hills SAFETY Operator Safety 4 amp WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn Z i S HOW TO AVOID THE HAZARD N Always follow proper procedure
91. tive 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 plugs for correct color 4 amp WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for inspection 1 Normal The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect fuel 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments Spark Plug Removal and Replacement 1 Remove the spark plug cap 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove 3 Reverse the procedure for spark plug installation Torque to 18 ft Ibs 24 Nm 89 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Ta
92. ubricate ETC Switch replace if necessary Choke cable 50H 500 800 Inspect adjust lubricate replace if necessary Carburetor air 50 H 500 800 Inspect ducts for proper intake ducts sealing air leaks flange Drive belt 50 H 500 800 Inspect adjust replace as needed Cooling system 50 H 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly Engine oil change 100 H 1000 1600 Perform a break in oil change at one month Oil filter change 100 H 1000 1600 Replace with oil change 100 H 1000 1600 Inspect adjust Fuel system 100 H 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years Radiator 100 H 1000 1600 Inspect clean external if applicable surfaces Cooling hoses 100 H 1000 1600 Inspect for leaks if applicable TSF T 600 pipe p Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California m Have an authorized Polaris dealer perform these services 66 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Maintenance Interval whichever comes first Calendar Miles Km E Spark plug 100 H 1000 1600 Inspect replace as needed Ignition Timing 100 H 1000 1600 Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc Clutches drive 100
93. uling cargo improperly can alter vehicle handling and may cause loss of control or brake instability and result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on one rack only increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK TH
94. urn 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 amp 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 27 SAFETY Operator Safety 4 amp WARNING 28 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 59 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads WARNING POTENTIAL HAZARD Improperly operating in reve
95. verride button on the left handlebar is also the mode button NOTE If using the mode button to program the rider information center or to toggle through the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the total hours the engine has been in operation Mode 4 Tachometer The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation 42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only Please return your ATV to your dealer for all major repairs As long as the gauge is in the diagnostic mode the wrench icon will remain lit To leave the diagnostic mode either shift the machine out of neutral or turn the key switch off and on NOTE Any movement of the tires will also take the machine out of the diagnostic mode To enter the diagnostics mode
96. witch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO NOTE The lights won t work unless the key is in the ON position and the auxiliary shut off switch is in the RUN position 4 amp WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Brake Lever The front and rear brakes are applied 1 by squeezing the brake lever 1 of toward the handlebar The front and E rear brakes are hydraulically 3 activated disc type brakes that are as activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 4 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 34 FEATURES AND CONTROLS Master Cylinder The brake fluid in the master 1 2 cylinder 1 which is located on the left handlebar shou

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