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Polaris 9921811 Offroad Vehicle User Manual

1. This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC 58 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest most reliable condition Inspection adjustment and lubrication of important components are explained in the periodic maintenance chart Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer Record maintenance and service in the Maintenance Log beginning on page 122 Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour 16 km h 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 crank case Change oil immediately if the oil level begins to rise Monitor
2. 3 6 mm toe out 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 1 Position the vehicle ona level surface 2 Place the handlebars in a straight ahead position 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your Polaris dealer for ser vice 77 MAINTENANCE 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 Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal 1 Remove the two screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the p
3. Pantone 426c CH POLARIS The Way Out ZUUL Sportsman 400 Owner s Manual for Maintenance and Safety 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 Pantone 426c AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For your nearest Polaris dealer PELARIS cal 1 800 POLARIS Hina eyy Oui or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9921822 Rev 02 Printed in USA AWARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm A card containing imp
4. Replace fuse Low battery voltage Recharge the battery to 12 8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Engine Turns Over Fails to Start Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plug s Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your deale
5. Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehi cles in your group When stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 41 OPERATION Pre Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake system lever travel Ensure proper operation H Brake fluid Ensure proper level 31 Auxiliary brake Ensure proper operation 30 Front suspension Inspect lubricate if necessary 63 Rear suspension Inspect lubricate if necessary 63 Steering Ensure free operation Tires Inspect condition and pressure 79 Wheels fasteners Inspect ensure fastener tightness i Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels Be Coolant level if applicable Ensure proper level th Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation ae Indicator lights switches Ensure operation 26 Engine stop switch Ensure proper operation 26 Air filter pre filter Inspect clean 82 Air box sediment tube Drain deposits wheneve
6. brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or sharp turns 7175511 23 SAFETY Safety Labels and Locations Tire Pressure Load Warning Rack Warning No Passenger Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa e Maximum weight capacity 385 Ibs 175 kg 7175442 24 SAFETY Safety Labels and Locations Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Rack Warning Front and Rear WARNING 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 e Max Rack Loads Front 70 Ibs 32 kg Rear 100 Ibs 46 kg 7173740 Reverse Override Warning WARNING Improper use of override button can lead to loss of control resulting in severe injury or death Do not activate override while throttle is engaged Always apply throttle gradually
7. while in reverse 7175486 4X4 Caution CAUTION Do not push switch to engage 4X4 AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage 7175485 Hitch Capacity Label TRAILER MAX WEIGHT 750 LBS 340 KG ON LEVEL GROUND HITCH MAX VERTICAL WEIGHT 75 LBS 34 KG 7173739 25 FEATURES AND CONTROLS Switches Headlight Switch Main Key Switch Mode Reverse Engine All Wheel Drive Override Stop Switch Switch Button Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button 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 modes of the rider information center See page 36 Engine Stop Switch _ gt Move the stop switch either left a or right to the OFF position to gi stop the engine quickly The Ss engine will not start or run when OFF RUN OFF the switch is off Both the main switch and the engine stop switch will shut off all electri cal power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page
8. 43 for starting pro cedures 26 FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights All Wheel Drive Switch See page 35 for all wheel drive information Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident Never start or operate an ATV that has a sticking or improperly operating throttle Always contact your dealer for service before operating the vehicle 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 Modifications to the electronic throttle control could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle control Engine speed and vehicle move on ment are controlled by pressing the i aa throttle lever The throttle lever is ps ES S spring loaded Engine speed returns f A E y to idle when the lever is released pt eae op This ATV is equipped with
9. 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug 89 MAINTENANCE PVT System A WARNING Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe e Always follow all recommended maintenance procedures See your dealer as outlined in the owner s manual e This PVT system is intended for use on Polaris products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 90 MAINTENANCE PVT System 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 Move the vehicle out of the water Remove the PVT drain plug Use a 17 mm wren
10. Maintenance Chart beginning on page 59 e Demand drive unit front gearcase e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated Fog the Engine 1 Treat the fuel system with Polaris Carbon Clean See page 101 2 Support the front end of the machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug Torque to specification 5 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the electric start Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 7 If Polaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 102 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 59 Battery Storage See pages 95 96 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover Do not use plastic or coated mate rials Th
11. OPERATION Driving on Slippery Surfaces Sideways _Turnin skid aon of ski O O AT ANY C C Ells E e a gt l C C Co c y S ESE Ww Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage AWD before wheels begin to lose traction NOTICE Severe damage to drive train may occur if AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 47 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly ter rain Improper procedure could cause loss of control or overturn When ever traveling uphill follow these precautions Drive straight uphill Avoid steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady rate of speed and throttl
12. OUT OF REACH OF CHILDREN Your ATV may have either a sealed battery which requires little mainte nance or a conventional battery A sealed battery can be identified by its flat covers on the top of the battery A conventional battery has six filler caps on the top of the battery Always keep battery terminals and connections free of corrosion If cleaning is necessary remove corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery 92 Battery Battery Removal 1 2 Place the transmission in gear Lock the parking brake Remove the splash shield behind the right front tire Remove the left side panel to access the battery hold down bracket Remove the screw at the bottom rear of the bracket and move the bracket aside Remove the battery cover On conventional batteries remove the battery vent tube MAINTENANCE Disconnect the black negative battery cable first Disconnect the red positive battery cable last Lift and remove the battery through the right wheel well If using a conventional battery be careful not to tip the battery sideways which could spill electrolyte NOTICE If electrolyte spills immediately wash it off with a soluti
13. authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may be required to present docu mentation of your move to Polaris Industries in order to continue your warranty cover age You may also be required to obtain documentation from Polaris Industries in order to register your vehicle in your new country 119 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you pur
14. change the handling char acteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle SAFETY Safety Warnings AWARNING Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Heed all safety warnings outlined in this section of the owner s manual See the OPERATION section of the owner s manual for proper operating procedures Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident The operator must understand how to operate the ATV properly in different situations and on different types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 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 10 SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive
15. cylinder Do not over m z Indicator 1 Position the vehicle on a Window level surface Make sure the handlebars are straight 2 View the fluid level through the indicator win dow eye on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Foot Brake The brake fluid reservoir is located in the front storage box Maintain the fluid level between the minimum and maximum marks Do not overfill 32 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 43 for correct choke and throttle settings during start ing Always refuel with the engine Cap stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap to add fuel to the fuel tank Use either leaded or unleaded gaso line with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve im The fuel valve is located on the bottom of the fuel tank Access p the fuel valve through the right aD side panel H7 ON For normal operation OFF For vehicle storage and when transporting Refuel when the instrument gauge indicates a low fuel level Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually D
16. engine starts NOTICE Operating the vehicle immediately after starting could cause engine 10 Tip 11 damage Allow the engine to warm up for several minutes before operating the vehicle If the engine does not start return the key to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts If a warm engine has cooled to a point where it does not readily start inter mittent use of the choke button pulled half way out may be necessary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in 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 accu mulation increases as outside temperature decreases See your Polaris dealer fo
17. parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use a 15 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 68 for recommendations 9 Add the recommended oil 10 Reinstall the fill plug Torque to specification See page 68 for recommenda tions 11 Check for leaks S 12 Dispose of used oil properly 70 MAINTENANCE Front Gearcase Demand Drive Fluig Always check and change the demand drive fluid at the inter vals outlined in the Periodic Maintenance Chart beginning on page 59 We recommend the use of Polaris Premium Demand Drive Hub Fluid Use of other oils may result in improper operation of compo nents See page 109 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drain plug is located on the bot tom right side of the gearcase Fill Plug Demand Drive Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Premium Demand Drive Hub Fluid Demand Drive Unit 5 oz 8 10 ft Ibs 8 10 ft Ibs 148 ml 11 13Nm 11 13 Nm 71 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Check 1 Position the vehicle on a level surface
18. 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 Obstructed cooling fan Clean any debris or mud that may be interfering with fan movement 113 SPECIFICATIONS Sportsman 400 HO 4X4 Maximum Weight Capacity 385 Ibs 175 kg includes weight of opera tor cargo and accessories Dry Weight 598 Ibs 271 kg Fuel Capacity 4 5 gal 17 D Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 2 qts 2 1 Transmission Oil 20 3 oz 600 ml Demand Drive Fluid 5 oz 148 ml Front Rack Capacity 70 Ibs 32 kg Rear Rack Capacity 100 Ibs 45 kg Hitch Tongue Weight Capacity 75 lbs 34 kg Rear rack capacity and tongue weight not to exceed 100 Ibs 45 kg Hitch Towing Rating 750 Ibs 340 2 kg Unbraked Trailer Towing Capacity 1786 lbs 810 kg Overall Length 73 in 185 cm Overall Width 44 in 112 cm Overall Height 46 in 117 cm Wheelbase 46 in 117 cm Ground Clearance 9 in 23 cm Minimum Turning Radius 69 in 175 cm unloaded Engine Model Number Type EH460PLE 4 Cycle Single Cylinder Ignition Timing Lubrication Dry sump Engine Cooling Liquid Displacement 455 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio
19. the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 59 MAINTENANCE Periodic Maintenance Chart AWARNING Improperly performing the procedures marked with a could result in component failure and cause an accident which may result in serious injury or death Always have an authorized Polaris dealer perform these services Maintenance Chart Key gt Perform these operations more often for vehicles subjected to severe use E Enmission related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions M Have an authorized Polaris dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km E Steering Pre Ride Make adjustments as need 7 7 ed See Pre Ride Checklist gt Front suspension Pre Ride on page 42 gt Rear suspension Pre Ride Tires Pre Ride gt Brake fluid level Pre Ride gt Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride gt Engine oil level Pre Ride gt Air filter pre filter Daily Inspect clean often replace E as needed gt Air box sediment Daily Drain deposits when visible tube Coolant Daily Check level daily
20. 10 1 1 Carburetor 34mm CV Mikuni Pilot Jet 42 5 Main Jet 157 5 Needle Jet P 6M 829 Jet Needle 41B33 Pilot Air Jet 160 Engine Idle 1375 100 RPM Ignition System DC CDI 14 2 1500 RPM 30 2 5000 RPM Spark Plug Gap NGK BKRG6E 035 in 0 9 mm Based on EU Directive 76 432 EC 114 SPECIFICATIONS Sportsman 400 HO 4X4 Driving System Type Automatic PVT Polaris Variable Transmission Shift Type Side Lever H N R Drive Ratio Front 3 6 1 Drive Ratio Final 15 18 1 Tires Pressure Front 24x8 12 5 psi 34 5 KPa Rear 24x11 12 5 psi 34 5 KPa Front Suspension MacPherson strut with 7 18 cm travel Rear Suspension Progressive rate with 8 20 cm travel Shock Adjustment CAM Brakes Front and Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 2 Dual Beam on Bumper 37 5 watt Taillights 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Standard Tripmeter Hour Meter Fuel Gauge Standard Jetting Chart AMBIENT TEMPERATURE ALDE Below 40 F 40 F and abov Meters Feet Below 5 C 448 C andabove 0 1800 0 6000 162 5 157 5 Above 1800 6000 150 145 Clutching Char
21. Fo 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Check the oil level 6 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads 7 Reinstall the fill plug Torque to specification See page 71 N 72 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Change 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 8mm Allen wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 71 9 Add the recommended fluid 10 Reinstall the fill plug Torque to specification 11 Check for leaks 12 Dispose of used oil properly 73 MAINTENANCE Cooling System 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 heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the con tracting cooled coolant is drawn back up from the bottle past the pre
22. NY PERSON FOR INCI DENTAL 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 117 WARRANTY ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR 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 limi tations on how long an implied warranty lasts so the above limitation may not apply to you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service you must take it to a Polaris dealer authorized to repair Polaris ATVs When requesting warranty service you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will co
23. Polaris A Electronic Throttle Control ETC which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear wheels will cease 27 FEATURES AND CONTROLS Brake Lever AWARNING 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 Always contact your dealer for service before operating the vehicle Squeeze the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 28 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1 Place the transmission in gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the parking brake lock E forward to engage the lock 4 Release the brake lever 5 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked posi
24. Turn the fuel valve off 51 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 52 Stop and lock the parking brake while keeping body weight uphill Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehi cle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill Start the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the brake lever until the vehicle is on more level ground OPERATION Driving Through Water Your ATV can operate through water with a maxi mum recommended depth equal to the bottom of the footrests Follow these pro cedures when operating through water 1 Determine water depths and current before entering water 2 Choose a crossing where both banks have gradual inclines Maximum Depth 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after
25. a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or any engine that has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of Polaris If you have any questions regarding your warranty rights and responsibilities you should contact the Polaris Warranty Department at 1 888 704 5290 121 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 122 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 123
26. ave your accessories and clothing delivered right to your door POLARIS The Way Out POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus tries Inc Copyright 2008 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 discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 2009 Sportsman 400 Owner s Manual P N 9921822 2 TABLE OF CONTENTS Introduction o cci onan tee Sere eoed enews 4 Safety 6 4 4 c dee ee SSS eR Eee Ot oes 7 Features and Controls 20 006 26 Operation ce 2 23 e isukun e eer we ie a 38 Emission Control Systems 58 Maintenance 000 eee eee eee 59 Adjustments 222002 cece eee 105 Polaris Products 020000 cease 109 Troubleshooting 00000e eee eee 110 Specifications fic sesh eh sees lee 114 Warranty fib ale Siena TORR ees 116 Maintenance Log 00ee0es 122 INDOX eve ee eee E ee 124 INTRODUCTION Th
27. bed in the owner s manual NOTE A special technique is required when braking while traveling down hill See page 50 e Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral e Always check the terrain carefully before descending a hill e Shift your weight rearward e 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 Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 49 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 52 15 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling rolling backwards or improperly dismounting while climbing a hill could cause an overturn e Always maintain a steady speed when climbing a hill If all forward speed is lost e Keep body weight uphill e Apply the brakes e Lock the parking brake when fully stopped e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around an
28. can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 106 Loosen the four handlebar bolts 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 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear bolts Handlebar Bolts ADJUSTMENTS Carburetor Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6 000 feet 1800 m and temperatures of 40 degrees F 4 degrees C or higher Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich and the engine loses approximately 3 of its power for each 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient opera tion Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C Tip Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV
29. capacity 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 only one rack 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 THE 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 surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in roug
30. ccident Operator and passenger must always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV Carrying a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 12 SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways may adversely affect the handling of the ATV and could result in loss of control and accident or overturn Avoid operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s unlawful to operate ATVs on public streets roads and highways Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator s risk of losing control Always operate at a speed that s appropriate f
31. ch a flat screw driver or the spark plug wrench Allow the water to drain com pletely Reinstall the drain plug Start the engine Place the trans mission in neutral Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear Test for belt slippage If the belt slips repeat the process Take the vehicle to your dealer for service as soon as possible 91 MAINTENANCE Battery AWARNING 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 AWARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP
32. change if applicable coolant every 2 years Headlamp tail Daily Check operation apply lamp dielectric grease if replacing 60 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter Weekly Inspect replace as needed E main element gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 20H Monthly 200 320 Check terminals clean test gt Front gearcase oil 25H Monthly 250 400 Inspect level change yearly if equipped gt Transmission oil 25H Monthly 250 400 Inspect level change yearly gt Engine breather 25H Monthly 250 400 Inspect clean if needed E filter if equipped gt General 50 H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50 H 6M 500 800 Drain bowl periodically and bowl prior to storage E Throttle Cable 50H 6M 500 800 Inspect adjust lubricate E ETC Switch replace if necessary E Choke cable 50H 6M 500 800 Inspect adjust lubricate E replace if necessary E Carburetor air 50H 6M 500 800 Inspect duct for proper seal intake ducts flange ing air leaks Drive belt 50H 6M 500 800 Inspect adjust replace as needed Cooling system 50H 6M 1000 1600 Inspect coolant strength if applicable seasonally pressure test system yearly
33. chase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions call Polaris Customer Assistance United States 1 888 704 5290 Canada 1 204 925 7100 120 WARRANTY U S A EPA Emissions Limited Warranty This All Terrain Vehicle ATV or Off Road Utility Vehicle ORUV emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle Polaris warrants that this vehicle is 1 designed built and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and 2 free from defects in materials and workmanship that may keep it from meeting these requirements The emissions warranty period for this vehicle begins on the date the vehicle is deliv ered to the original retail purchaser and ends 30 months 2 5 years after that date after 5000 km 3100 miles or after 500 hours of operation whichever comes first This emission related warranty covers compone
34. cident especially if operating on a road or street This ATV is not equipped with highway approved lights Operate this vehicle off road only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights frequently and replace burned out headlamps promptly 20 SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident 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 Physical Skills 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 Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle which could result in an accident or overturn Always remove the ignition key when the vehicle is not in use 21 SAFETY Safety Labels and Locations Warning labels have been placed on the v
35. d remount following the procedure described in the owner s manual See page 52 If the ATV begins rolling downhill Keep body weight uphill e Never apply engine power e 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 e 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 52 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees 16 SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain Always use extra caution on rough slippery or loose terrain Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert t
36. d until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD NOTICE 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 35 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel The instrument cluster measures distance in miles 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 he Y 11 14 km h Refer to page 26 ag for additional information NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster Miles Kilometers Toggle The display in the tripmeter odometer and speedometer can be changed to display
37. e following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions 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 such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a Polaris ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course Purchasers
38. e for two minutes Stop the engine Check for oil leaks Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range Add Oil Safe Reinstall the dipstick Discard used oil and filter properly 67 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 Maintain the oil level at the bottom of the fill plug hole See page 109 for the part numbers of Polaris products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Drain Plug Torque Torque Transmission Premium AGL Synthetic 20 3 oz 15 ft Ibs 15 ft Ibs Gearcase Lubricant 600 ml 20 Nm 20 Nm 68 MAINTENANCE Transmission Oil Oil Check 1 Position the vehicle on a level surface Fo 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Check the oil level 6 Add oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification See page 68 for recom mendations 69 MAINTENANCE Transmission Oil Oil Change 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the
39. e opening Opening the throttle suddenly could cause the ATV to flip over backwards oO ee Oa 8 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 48 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 av Re oe Slow down Avoid crossing the side of a steep hill Shift body weight uphill Keep your feet on the footrests If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 49 OPERATION Driving Downhill When driving downhill follow these precautions 1 2 3 4 50 Avoid steep hills 25 maximum Shift body weight uphill Drive straight downhill Slow down Excessive speed when traveling downhill can cause loss of control Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of con trol OPERATION Parking on an Incline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine Place the transmission in gear Lock the parking brake Always block the rear wheels on the downhill side etn aa end
40. e stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 2 Install the wheel nuts finger tight 3 Lower the vehicle to the ground 4 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications 90 ft Ibs 122 Nm O CAST ALUMINUM STEEL Check the wheel nut torques occasionally and when they ve been loos ened for service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft Ibs 37 Nm 81 MAINTENANCE Air Filter 1 Position the vehicle on a level Foal surface Place the transmission a Ae in gear 2 Lock the parking brake 3 Remove the seat 4 Release the air box cover clips Pre Filter and remove the air box cover 5 Loosen the clamp and remove the filter 6 Remove the fabric type pre fil ter from the main filter Wash the pre filter in soapy water then rinse and let dry 7 Reinstall the pre filter over the main filter Install a new main filter if needed 8 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Breather Filter 9 Reinstall the air box cover and the seat 82 MAINTENANCE Breather Filter Hose 1 Remove the left s
41. e total hours the engine has been in operation 37 OPERATION Failure to operate the ATV properly can result in a collision loss of control accident or overturn which may result in serious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use 38 OPERATION Break In Period Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 33 Always exercise extreme caution whenever handling gasoline 2 Check the oil level on the dipstick See page 65 Add oil if neces sary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid
42. eck the brake fluid level fre quently for the auxiliary brake system 30 FEATURES AND CONTROLS Brake Fluid A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in an accident Maintain brake fluid at the recommended level Do not overfill 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 brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check brake fluid levels for both brake systems before each ride Always maintain brake fluid at the recommended level Do not overfill If the fluid level is low add DOT 4 brake fluid only See page 109 for the part numbers of Polaris products Under normal operation the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill 31 FEATURES AND CONTROLS Brake Fluid Hand Brake Master Cylinder The master cylinder is located on the left handlebar Main tain the fluid level 1 4 6 3 mm below the top edge of the master
43. ehicle for your protection Read and follow the instructions on each label carefully If any of the labels shown in this manual differ from the labels on your vehicle always read and follow the instructions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge The part number is printed on the label General Warning WARNING Improper ATV use can result in f SEVERE INJURY or DEATH _ ALWAYS USE AN APPROVED a HELMET AND PROTECTIVE fT GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle e 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 ter rain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 22 SAFETY Safety Labels and Locations Discretionary Warning WARNING Never operate this ATV on HILLS steeper than 25 degrees 25 To prevent overturn on hilly terrain use throttle and
44. either kilometers or miles 1 To change modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 Inthe odometer mode press and hold the mode button until the let ters flash then release the button 3 Press and release the button one more time When the display stops flashing the mode has been set 36 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster All seg ments will light up for 3 seconds at start up 1 Gear Indicator This indicator displays gear shifter position N Neutral Green R Reverse Amber 2 Engine Hour Display Indicator 3 Speedometer 4 Odometer Tripmeter Hour Meter Modes Use the reverse override mode button to toggle through the 3 standard modes Tip If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the ATV Trip Meter The trip meter records the distance traveled by the ATV on each trip if it s reset before each trip To reset the trip meter toggle to the trip meter mode Press and hold the mode button until the display changes to 0 In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter This mode logs th
45. engine sump the sump should also be drained Draining the engine sump will require additional oil not contained in the oil change kit The total oil capac ity of the engine sump and oil tank combined is 2 25 qts 2 1 liters 1 Position the vehicle on a level sur face 2 Place the transmission in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the oil tank drain plug 6 Place a drain pan under the oil tank 7 Remove the drain plug Use a 14 mm wrench 8 Drain the oil CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 9 Reinstall the oil tank drain plug The sealing surfaces on the drain plug and oil tank should be clean and free of burrs nicks or scratches 10 Torque to specification See page 64 66 MAINTENANCE Oil and Filter Change 11 12 13 14 15 16 17 18 19 20 21 22 23 Place towels under the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it Clean the filter sealing area on the engine Lubricate the filter o ring Check to make sure the o ring is in good condition Install the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand Remove the dipstick Add the recommended oil See page 64 Reinstall the dipstick Start the engine Allow it to idl
46. erious engine damage Always use Polaris recommended spark plugs Plug Condition Torque Specification New Spark Plug 9 11 ft Ibs 12 15 Nm Previously Installed Spark Plug 17 20 ft lbs 23 27 Nm Spark Plug Inspection Spark plug condition is indicative of engine operation Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 87 CAUTION A hot exhaust system and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Remove the seat Remove the right side panel 2 Remove the fuel tank cover 3 Rotate the spark plug cap 1 4 turn and pull it off the spark plug If necessary use a needle nose pliers to assist 4 Using a 5 8 socket with a long extension access the spark plug through the fuel tank cover opening Rotate the spark plug counterclockwise to remove it 5 Reverse the procedure for spark plug installation Torque to specification 86 MAINTENANCE Spark Plugs Spark Plug Condition Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an imprope
47. ey do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has a wide range of additional accessories available for your ATV Always install accessories that are approved for ATV use Please see your Polaris dealer 103 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle Stop the engine Place the transmission in gear Lock the parking brake Turn the fuel valve off Secure the fuel cap oil cap and seat Remove the key to prevent loss during transporting SON ee ee Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 104 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Spring Adjustments The front and rear shock absorber springs are adjustable Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension Always adjust both sides equally Accessory springs are available through your Polaris dealer 105 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts
48. for conditions in your area Carburetor Engine Idle RPM Adjustment If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Place the transmission in gear 2 Lock the parking brake 3 Start the engine and allow it to warm up for approximately five minutes 4 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM Adjuster 107 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 2 108 Locate the throttle cable adjuster at the handlebar Squeeze the end of the rub ber boot and slide it far enough to expose the end of the inline cable adjuster Loosen the adjuster lock nut Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever While adjusting freeplay be sure to flip the throttle lever back and forth Tighten the lock nut Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Boot Lock Nut Adjuster Part POLARIS PRODUCTS Number Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil qt 2876245 PS 4 PLUS Performance Synthetic 2W 50 4 Cycle Oil gal Gearcase Transmis
49. front of the vehicle Battery Charging Sealed Battery The following battery charging instructions apply only to the installa tion 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 or dealership Never pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage WARNING An overheated battery 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 96 MAINTENANCE Battery Battery Charging Sealed Battery For a refresh charge follow all Attach black instructions carefully Check voltage ground clamp here here 1 Measure battery voltage at the starting solenoid near the radiator cap under the front storage cover Check the battery voltage with a voltmeter or multimeter 2 To recharge carefully attach the RED charger clamp to the red cable on the solenoid This is the same terminal used to measure the battery voltage 3 Attach the BLACK clamp to the starting solenoid bracket Tip A fully charged ba
50. g procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCourse by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury x Eye Protection 5 ee Long Sleeves Helmet Wearing a helmet can prevent a severe head injury Whenever riding a Polaris vehicle always wear a helmet that meets or exceeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle
51. g so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 1 c Violations are subject to monetary penalties Fed eral regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The vehicle compliance labels can be found on the frame tubing of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian ICES 002
52. gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at 20 hours gt Oil filter change 100 H 6M 1000 1600 Replace with oil change gt Oil tank vent hose 100 H 6M 1000 1600 Inspect routing condition if equipped p Valve clearance 100 H 12M 1000 1600 Inspect adjust E Fuel system filter 100 H 12M 1000 1600 Check for leaks at tank cap E lines fuel valve filter pump carburetor replace lines every two years 61 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Radiator 100 H 12M 1000 1600 Inspect clean external if applicable surfaces gt Cooling hoses 100 H 12M 1000 1600 Inspect for leaks if applicable gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe Spark plug 100 H 12M 1000 1600 Inspect replace as needed p Ignition Timing 100 H 12M 1000 1600 Inspect gt Wiring 100 H 12 M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc E Clutches drive 100 H 12M 1000 1600 Inspect clean replace worn and driven parts E Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings E Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clea
53. h terrain while cornering or while ascending or descending a hill 56 Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual 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 Towing Loads OPERATION Always attach a towed load to the hitch point Remove the hitch from the ATV when not towing a trailer If towing a load reduce rear rack cargo weight by the amount of tongue weight e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity e The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 4 10 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use Maximum 4 10 cm 57 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doin
54. have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips e Avoid the use of automotive products some of which can scratch the finish of your vehicle e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 99 MAINTENANCE Cleaning and Storage Chrome Wheel Care if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light ru
55. he best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Usea professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish 98 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water may damage components and could remove paint and decals Avoid directing the water stream at the follow ing items e Wheel bearings e Radiator if equipped e Transmission seals e Brakes e Cab and body panels e Labels and decals e Coolant if equipped test strength fill s e Electrical components e Switches and controls If an informational or graphic label becomes illegible or comes off con tact your Polaris dealer to purchase a replacement Replacement safety labels are provided by Polaris at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may
56. he procedure on page 91 for drying out the PVT MAINTENANCE Spark Arrestor AWARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death Never run the engine in an enclosed area 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 go under the vehicle while it s inclined The exhaust system can get extremely hot Do not perform service on the spark arrestor while the system is hot Allow components to cool sufficiently before proceeding Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Position the vehicle on a level surface 2 Place the transmission in neutral 3 Lock the parking brake x 4 Remove the arrestor M T clean out plug from the Clean Out Plug bottom of the muffler 5 Start the engine 6 Quickly squeeze and release the throttle lever several times to purge carbon from the system 7 If carbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 8 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 6 9 If particles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 10 Place the transmission in neutral Lock the parking brake Repeat steps
57. ide panel See page 78 2 Remove the hose clamps from the filter and pull the filter out of the hoses Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace a damaged or clogged filter 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed Reinstall the filter and hose clamps The filter is effective with the arrow pointing in either direction NOTICE Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 83 MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 99 84 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in neutral Lock the parking brake Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height Include rider weight on the seat when measuring Start the engine Turn the headlight switch to high beam Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall Loosen the phillips screw at the rear of the headlamp Adjust the beam Tighten the screw MAINTENANCE Lights Poor lighting ca
58. in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 116 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 rac ing 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 com ponents or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO A
59. ing steam can cause 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 Open the front storage box cover 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radia tor filler neck 4 Reinstall the pressure cap Use of a non standard pres sure cap will not allow the recovery system to func tion properly Contact your dealer for the correct replacement part 5 Secure the box cover 75 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar The auxiliary foot brake is also hydraulic Both brake systems are self adjusting Brake Inspections 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 1 Always keep brake fluid at an adequate level See page 31 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 Replace the pads when the fric tion material is worn to 03 8 mm 5 Check the security and surface condition of the disc 76 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4
60. lastic rivets securing the footwell to the fenders 3 Remove the footwell Screws Rivets 78 MAINTENANCE Tires AWARNING 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 Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle Always use original equipment size and type when replacing tires Refer to the specifications section beginning on page 114 for recom mended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm when tread depth is worn to 1 8 3 mm or less PS Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer 79 MAINTENANCE Tires Wheel Removal 1 Position the vehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your Polaris dealer 5 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 6 Remove the wheel nuts 7 Remove the wheel 80 MAINTENANCE Tires Wheel Installation 1 Place the wheel on the wheel hub with the valv
61. le is not used for a period of three months or more remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge Polaris recommends maintaining battery charge by using a Polaris Bat tery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 109 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery L will deteriorate rapidly Check ati Upper the battery fluid level often Maintain the fluid level between the upper and lower level marks Add only distilled water Tap water contains minerals that are harmful to a battery YB14 B rsx 4011359 W YUASA KANES ct 95 MAINTENANCE Battery Battery Charging Conventional Battery 1 Remove the battery from the vehicle to prevent damage from leak ing or spilled electrolyte during charging See page 93 2 Charge the battery with a charging output no larger than 1 10 of the battery s amp hr rating Charge as needed to raise the specific grav ity to 1 270 or greater 3 Reinstall the battery See page 94 Make sure the positive terminal is toward the
62. levels controls and areas outlined on the daily pre ride inspection checklist See page 42 6 Pull only light loads 7 Change both the oil and the filter at 20 hours or one month which ever comes first PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 39 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 40 Complete the recommended safety training before operating this vehicle See page 7 Do not allow anyone under 16 years of age to operate this vehicle Do not allow anyone with cognitive or physical disabilities to oper ate this vehicle Never carry a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliary brake for emer gency situations if service brakes become inoperable Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness Clean headlights fre quently and replace burned out headlam
63. n out Idle speed Adjust as needed E Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 62 Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri odic Maintenance Chart beginning on page 59 Items not listed in the chart should be lubricated at the General Lubrication interval MAINTENANCE Unit Front Gearcase Hub Fluid Item Lube Method Engine Oil PS 4 PLUS Performance See page 64 Synthetic 2W 50 Brake Fluid DOT 4 Only See page 31 Transmission Oil Polaris AGL Synthetic See page 68 Gearcase Lube Front Demand Drive Premium Demand Drive See page 71 Front Prop Shaft Yoke Control Arm front and rear Bearing Carrier Transmission upper pivot point Polaris Premium U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles 800 km before long periods of storage or after pressure washing or sub merging pine Front Prop Shaft Yoke Bearing Carrier Transmission Upper Pivot Point 63 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS 4 PLUS Performance Syn thetic 2W 50 4 cycle oil or a similar oil for this engi
64. n result in reduced visibility when driving Headlight and taillight lenses become dirty during normal operation Clean lights frequently and replace burned out lamps promptly Always make sure lights are adjusted properly for best visibility Headlamp Replacement 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 1 Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly CAUTION Hot components can cause burns to skin Allow lamps to cool before servicing 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 Lamp Replacement 1 From the rear of the brake light remove the two screws holding the lens cover in place Remove the lens cover 2 Remove the lamp and replace it with a new lamp 3 Test the light for proper o ERTER H H operation l Ne 4 Reinstall the lens cover A Cover L een Screw 85 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 114 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in s
65. ne Oil may need to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Specifications Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance 2 ats 1 9 I 14 ft Ibs 19 Nm Synthetic 2W 50 4 Cycle Oil 64 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the left front tire 1 2 3 Position the vehicle on a level surface Place the transmission in neutral Lock the parking brake Clean away all dirt and debris on the oil tank or in the wheel well area Start the engine Allow it to idle for 30 seconds Stop the engine Remove the dipstick Wipe it dry with a clean cloth Reinstall the dipstick completely Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill Safe Range Add Oil Safe Reinstall the dipstick 65 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 59 To change the oil properly always drain the oil tank and change the oil filter If oil contamination water mud metal shavings is suspected in the
66. nspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your dealer 112 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Overuse of choke Inspect clean and or replace spark plugs Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure See your dealer Overheated engine Engine Overheating Possible Cause Low radiator coolant level Clean radiator screen and core clean engine exterior see your dealer Solution Add coolant Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove
67. ntact 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 rec ommend the use of Polaris engine oil for your ATV 2 Damage resulting from the use of non recommended lubricants may not be covered by warranty SPARK ARRESTOR Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require ments of 43 CFR 8340 1 c for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with Polaris recommendations 118 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WAR RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCA TION This policy does not apply to vehicles that have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s
68. nts whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recircula tion aftertreatment or any other system utilized in this vehicle to control emissions Replacing or repairing other components not covered by this emissions warranty or the standard warranty is the responsibility of the owner including the parts labor and other costs associated with recommended maintenance The exclusive remedy for breach of this limited warranty shall be at the exclusive option of Polaris repair or replacement of any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR TICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply if it is incon sistent with the controlling state law This limited warranty excludes failures not caused by
69. o changing terrain conditions 17 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 55 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always maintain proper tire pressure as described in the owner s manual and on safety labels 18 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme caution and always follow proper operating procedures as outlined in this manual See page 54 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces Operating Through Deep Water Operating the ATV through deep o
70. o not attempt to clean the fuel filter 33 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is Gear located on the right side of the vehi Selector g5 cle N H High Gear N Neutral R Reverse To shift gears brake to a complete stop When the engine is idling move the lever to the desired gear NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 34 FEATURES AND CONTROLS All Wheel Drive AWD System The All Wheel Drive system is controlled by the AWD switch When the switch is on 2X4 the ATV is in two wheel drive at all times When the switch is on AWD the ATV is in all wheel AWD drive Switch When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain trac tion the demand drive unit will automatically disengage Tip The override switch allows activation of AWD in reverse if the AWD switch is on See page 26 There is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enable
71. of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourses Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourses e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 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 safety training course INTRODUCTION Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Engine Serial Number Key Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETY Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV RiderCourse available to you and your eligible family members This training is included in the purchase price of your ATV Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourses You were also provided with printed materials that explain safe operatin
72. on of one tablespoon baking soda and one cup water to prevent damage to the vehicle 93 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat tery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 96 before installing the battery 1 Ensure that the battery is fully charged 2 Place the battery in the battery holder 3 With conventional batteries install the battery vent tube sealed bat teries do not have a vent tube The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cause an explosion resulting in serious injury or death Always ensure that the vent tube is free of obstructions and is securely installed as recommended 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly Connect and tighten the red positive cable first Connect and tighten the black negative cable last Install the battery cover and hold down bracket 0 ON Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 9 Reinstall the left side panel and the right splash guard 94 MAINTENANCE Battery Battery Storage Whenever the vehic
73. operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse BON ee Se Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE 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 55 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight
74. operation in water Perform the services outlined in the maintenance chart See page 59 The following areas need special attention engine oil transmission oil front and rear gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 88 then see your dealer for service at the first opportunity 4 After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads If it s unavoidable to enter water deeper than the footrest level e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 53 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 1 2 54 Always check for obstacles before operating in a new area Look ahead and learn to read the terrain Be constantly alert for haz ards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible Never attempt to
75. or the terrain the visibility and operating conditions and your experience 13 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual See page 48 14 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn e Always follow proper procedures for travel ing down hills as descri
76. ortant ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance 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 e Snowmobiles e All terrain vehicles ATVs e RANGER utility vehicles e Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre ational vehicles manufactured in the world today Many years of experi ence 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 ser vice needs during and after the warranty period We also take great pride in our complete line of apparel parts and acces sories available through our online store at www purepolaris com H
77. ps promptly Drive in a manner appropriate for your skills and operating condi tions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the handle bars while operating and always keep both feet on the footrests Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water Do not touch hot exhaust system components Always keep com bustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the opera tion of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by con tacting your Polaris dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails
78. r 111 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Idle set too low Adjust idle speed Engine Runs Irregularly Stalls or Misfires Possible Cause Solution Fouled or defective spark plug s Inspect clean and or replace spark plug s Worn or defective spark plug wires See your 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 tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change fuel clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting Possible Rich Fuel Cause Overuse of choke See your dealer Solution I
79. r engine heater kits which provide quicker warm ups and easier starting in colder weather 44 OPERATION Driving Procedures N e S a E Wear a helmet and eye protection See page 8 Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up 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 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces 45 OPERATION Turning the Vehicle 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 tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 46
80. r fast flowing water could cause the tires to float causing loss of control or overturn 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 53 e Travel slowly e Balance your weight carefully e Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes e Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 19 SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cause loss of control or an accident e Never exceed the stated load capacity for this ATV e Cargo should be properly distributed and securely attached e Reduce speed when carrying cargo or pulling a trailer Allow a greater dis tance for braking e Always follow the instructions in the owner s manual for carrying cargo or pull ing a trailer Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or ac
81. r spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil improper use of the choke or incorrect throt tle body carburetor adjustments 87 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine If it s impossible to take your ATV to a dealer before starting it follow the steps outlined below 1 10 11 12 88 Move the vehicle out of the water Turn the fuel valve off Check the air box If water is present dry the air box and replace the filter with a new filter Remove the spark plug Loosen the carburetor drain screw and drain the carburetor Turn the engine over several times AE using the electric start AN Dry the spark plug Reinstall the 4 j plug or install a new plug hy J Drain Screw Tighten the carburetor drain screw Turn the fuel valve on Attempt to start the engine If necessary repeat the drying proce dure Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not If water has been ingested into the PVT follow t
82. r visible Headlamp Check operation apply Polaris dielec 27 tric grease when lamp is replaced 85 Brake light tail lamp Check operation apply Polaris dielec 85 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 8 protective clothing 42 OPERATION Starting the Engine The variable choke is fully on Position the vehicle on a level surface outdoors or in a well venti lated area Place the transmission in neutral Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Turn the fuel valve on Sit on the vehicle Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled If the engine is cold pull the choke knob out until it stops when the knob is pulled com pletely out The choke is off when the knob is pushed com pletely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components Move the engine stop switch to RUN Do not press the throttle while starting the engine 43 OPERATION Starting the Engine 9 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
83. s sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant 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 109 for the part numbers of Polaris products Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located under the front storage box cover near the radiator cap Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 1 Position the vehicle on a level surface 2 Open the front storage box cover 3 View the coolant level 4 Add coolant as needed 74 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water Replace the coolant any time the cooling system has been drained for maintenance or repair If the recovery bottle has run dry check the level in the radiator Add coolant as needed CAUTION Escap
84. s With the transmission in neutral advance the throttle to about 1 8 throttle in short bursts 5 to 7 times The belt will become more flex ible and prevent belt burning Slow easy clutch engage ment Use the throttle quickly and effectively Towing pushing at low RPM low ground speed Use low range only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 91 Inspect clutch seals for damage if repeated leaking occurs Clutch malfunction See your Polaris dealer Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines See your dealer Slippage from failure to warm up belt Always warm up the belt by operating below 30 mph 48 km h for one mile 1 6 km Operate 5 miles 8 km or more when temperature is below freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 39 110 Engine Doesn t Turn Over Possible Cause Blown fuse TROUBLESHOOTING Solution
85. sion Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2870465 Pump for Gallon Jug 2871654 Premium Demand Drive Hub Fluid 8 oz 2872277 Premium Demand Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 3 8 I 2871534 60 40 Coolant qt 95 I Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 02 2871515 Premium U Joint Lube 3 02 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 oz 2872348 Chain Lube Aerosol 16 oz Additives Miscellaneous 2871326 Carbon Clean Plus 12 oz 2870652 Fuel Stabilizer 16 oz 2872189 DOT4 Brake Fluid 12 oz 2871956 Loctite 565 Thread Sealant 2859044 Polaris Battery Tender Charger 109 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Driving onto a pickup or tall trailer in high range Solution Use low range if equipped Starting out going up a steep incline Use low range if equipped or turn around using the K turn see page 52 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range if equipped more frequently Insufficient warm up at low ambient tempera tures Warm the engine at least 5 minute
86. st 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 out lined above 100 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as recommended See page 98 Stabilize the Fuel 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust systems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 66 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter See page 83 4 Drain the sediment tube 101 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Change fluids as recommended in the Periodic
87. surrounding the letter E followed by the distinguishing number of the country which has 051039 granted approval The approval number and serial 0006 31 number will also be displayed on the label SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a Polaris vehicle always wear shatterproof goggles or use a shatterproof helmet face shield Polaris recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels 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 Equipment Modifications 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 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 The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may
88. t Altitude Roller Number of Rollers Driven Clutch Meters Feet Weight Spring 0 1500 0 5000 19 5 g 5413447 8 7043395 1500 3000 5000 10000 17 g 5412975 8 7043395 3000 10000 16 g 5412991 8 7043395 115 WARRANTY LIMITED WARRANTY Polaris Sales Inc 2100 Highway 55 Medina MN 55340 gives a SIX MONTH LIM ITED WARRANTY on all components of the Polaris All Terrain Vehicle ATV against defects in material or workmanship Polaris also gives a one year limited warranty on the final drive chain for failure due to defects This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty This warranty begins on the date of purchase This warranty is transferable to another consumer during the warranty period through a Polaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your ATV is very important
89. tion WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 29 FEATURES AND CONTROLS Auxiliary Foot Brake AWARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Never back down a hill 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 which may result in serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake The auxiliary foot brake is Auxiliary Foot located on the inside of the Marake i right footrest Operate this brake with your right foot If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Ch
90. ttery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery volt age is 12 8 or greater When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the following guidelines for recharging Always verify battery condition before and 1 2 hours after the end of charging State of Charge TIME Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months 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 97 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components NOTICE High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle T
91. under certain conditions e Always exercise extreme caution whenever handling gasoline e 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 refu eling 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 Turn the fuel valve off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run in an enclosed area 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 Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident Always inspect the ATV before each use to make sure it s in safe operating condition Always follow all inspection and maintenance procedures and schedules described in the owner s manual 11 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an a

Polaris 9921811 Offroad Vehicle User Manual

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