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Polaris 9920629 Offroad Vehicle User Manual

1. 00 000 118 Active Descent Control Fluid 86 87 Active Descent Control System 45 ADC System 0 4 45 Age Restrictions 12 Air Filter pen eeri niiin i ii 95 All Wheel Drive System 44 Auxiliary Foot Brake 90 AWD Switch 44 AWD System see eener asrar raso 44 B Battery Charging Conventional 111 Charging Sealed 111 112 Conventional 107 Fluid Conventional 110 Installation 109 Removal 108 Storages i eae Bare a eee 110 Belt Liteac wacd nas ate ges 42 BOOts iy fase 2st gad ausa ars iya a 11 Brake Fluid Auxiliary Foot Brake 40 Brake Fluid Main Brake System 38 Brake Lever 37 Brake Foot 40 90 Brake Hand Lever 90 Brake Parking 39 Brakelight Lamp Replacement 99 Brakes ian sa ee cone catia eee 90 Break In Period 53 Breather Filter 95 Breather Hose 95 C Camber Adjustment 120 Carburetor 000 121 Carburetor Adjustment 121 Cargo Loading 58 59 Caster Adjustment 120 Chokes sary bout i hie AEAN 41 Chrome Wheel Care 115 Cleaning and Storage 113 118 Clock Setting Time 49 Clothing ionns eee eel cane 11 Clutching Chart 129 Cold Weather Operation
2. a 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 Part No 9920629 Rev 02 a M PRINTED IN THE USA POLARIS The Way Out i AWARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card or if it has 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
3. 90 Toe Alignment MAINTENANCE A WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an authorized Polaris dealer Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 8 to 1 4 3 6 mm toe out l NOTE Place the handlebars in a straight ahead position Place stands in front of the vehicle per pendicular to the rear tires Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle Measure the dis tance from the string to the rim at the front and rear of the front rim Rear measure ment should be 1 16 to 1 8 2 3 mm more than the front measurement o String Rear of Front Rim Front of Pa Front Rim Stands If you discover improper alignment see your Polaris dealer for service 91 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 rear of the side panel near the rear cab With a firm motion pull the panel outward to disen
4. 108 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 111 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 NOTE The vent tube must be free of obstructions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte A 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 Secure the battery hold down strap Verify that cables are properly routed NOTE Cables should be safely tucked away at the front and rear of the bat tery CW IAW 109 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more remove the battery from the vehicle e
5. Spark arrestor 300 H 36M 3000 4800 Clean out Idle speed Adjust as needed 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 Have an authorized Polaris dealer perform these services 76 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 72 Items not listed in the chart should be lubricated at the General Lubrication interval NOTE The a arms and lower control arms are lubricated at the factory and no additional lubrication will be needed However if these components are subjected to severe use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Method Engine Oil Polaris Premium 4 Synthetic Add to proper level on dipstick ow40 Brake Fluid DOT 4 Only Maintain level between fill lines See page 38 Transmission Oil Polaris AGL Synthetic See page 83 Gearcase Lube Demand Drive Fluid Demand Drive LT Premium See page 84 Front Gearcase Fluid ADC Fluid Polaris ADC Fluid Maintain level between fill lines See page 86 Front Prop Shaft Yoke Polaris Premium U Joint Grease fittings 3 pumps maxi Lube mum every 500 miles before long periods of storage or after press
6. 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 Have 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 2006 Polaris Sales Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrep ancies may result be
7. A WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the ATV with a spongy feeling brake lever 37 FEATURES AND CONTROLS Master Cylinder Brake Fluid Check the brake fluid in the master Master Cylinder cylinder before each ride The fluid level can be seen through an indicator window on the top of the master cylinder This eye will appear dark when the fluid level is full When fluid is low the eye will be clear NOTE When checking the fluid level the ATV must be on Indicator level ground with the handle Window bars straight If the fluid level is low add DOT 4 brake fluid only See page 127 for the part numbers of Polaris products A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill A WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or severe injury After opening a bottle of brake fluid always discard any unused portion 38 FEATURES AND CONTROLS Parking Brake A WARNING Operating the ATV while the parking brake is engaged cou
8. 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 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 1 763 417 8650 135 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 136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 137 INDEX A Accessories
9. eee e ee ee 52 Fuel Tank Cap 0 41 Fuel Valve 0 0 41 G Gear Selector 0 42 GIVES a secs Sas ea aes 11 H Hand Brake 0 90 Handlebar Adjustment 120 Hauling Cargo 58 59 Headlight Housing Replacement 98 Headlight Lamp Replacement 96 Headlight Switch 35 Helmets daden eha oe fara ties 10 High Beam Adjustment 97 High Range Use 106 l Idle RPM Adjustment 121 Immersion Maintenance 102 Instrument Cluster 46 51 J Jetting Chart 02 129 K Key Switch 35 WS TUPI os ate a sce E atn tet sacs 66 L Lights Headlight Housing 98 Headlight Lamp 96 High Beam Adjustment 97 Low Beam Adjustment 97 Lower Headlamp Replacement 99 Taillight Brakelight Worklight 99 Low Beam Adjustment 97 Low Range Use 106 Lower Headlamp Replacement 99 Lubrication Guide 77 M Maintenance Chart 72 76 Master Cylinder 38 Mode Switch 34 Modifications 18 N Noise Emission Control System 71 0 Oil Engine 78 79 Transmission 83 84 Oil and Filter Change 80 82 Oil Level Engine 79 Oil Pump Priming 82 Oil Recommendations 78
10. reducing the amount of belt pinch On Polaris ATVs the approximate gear ratio difference between high and low range is 1 2 25 This difference in gearing affects the operation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts wears clutch components and causes outer clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch cover extends the life of the PVT components belt cover etc 105 MAINTENANCE PVT System When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavy loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drying There may be some instances when water is accidently
11. the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not disengage until the rear wheels regain traction Engage the AWD switch before getting into conditions where front wheel drive may be needed If the rear wheels are spinning release the throttle before switching to AWD CAUTION Switching to AWD while the rear wheels are spinning may cause severe drive shaft and gearcase damage Always switch to AWD while the rear wheels have traction or are at rest 44 FEATURES AND CONTROLS Active Descent Control ADC System The ADC system if equipped allows engine braking to all four wheels when the vehicle descends a hill or incline If your ATV is equipped with Active Descent Control always engage AWD before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the follow ing conditions occur The AWD switch must be in the AWD position e Vehicle speed must be 15 mph 24 km h or less e The throttle must be closed throttle lever released The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the fol lowing conditions occur e The AWD switch is moved to the 2X4 position e Vehicle speed exceeds 15 mph 24 km h
12. Cluster LCD Jetting Chart ALTITUDE z Paaa eE Meters Feet elow 40 40 F and above Below 5 C 5 C and above 0 1800 0 6000 175 167 5 1800 3700 162 5 157 5 6000 12000 Clutching Chart Altitude Shift Drive Clutch Driven Helix and Weight Spring Clutch Spring Spring Setting Meters 0 1800 10 WH Blue Gray Black 40 Feet 0 6000 PN 5630710 PN 7042202 PN 7041782 PN 5131446 2 2 1800 3700 20 40 Blue Gray Black 40 6000 12000 PN 5631356 PN 7042202 PN 7041782 PN 5131446 2 2 129 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 purchas
13. 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 11 SAFETY Operator Safety A WARNING Failure to follow the warnings contained in this manual can result in severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operating a Polaris ATV Age Restrictions This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age 12 SAFETY Operator Safety Safety Training ATV safety training is a top priority for Polaris When you purchased your new ATV your dealer instructed you on the authorized ATV 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 y
14. NOTE The transmission cannot be in reverse when using this feature Odometer Mode The odometer records the miles traveled by the ATV Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been in operation Tachometer Mode The engine RPM is displayed digitally NOTE Small fluctuations in the RPM from day to day may be normal because of changes in humidity temperature and elevation Clock Mode The clock displays time in a 12 hour format To reset the clock see page 9 48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode To exit the diagnostic mode turn the key switch off and on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 2 3 4 5 Turn the key switch off and wait 10 seconds Lock the parking brake Place the transmission in neutral Hold the mode reverse override button and turn the key switch on Release the switch as soon as the display is
15. Operation on Public Lands 71 Operator Safety 12 33 Override Switch 34 P Parking Brake 39 Parking on an Incline 70 Periodic Maintenance Chart 72 76 Polaris Product List 127 Polishing the Vehicle 114 Pre Ride Checklist 54 PVT Break In 53 PVT Dryin i Asseh copy aude 106 PVT System 104 106 R Recoil Housing 101 Recoil Starter 43 Reverse Operation 69 Reverse Override Switch 34 Rider Information Center 47 51 Riding Gear 10 11 S Safety Decals No Passenger Warning 8 Age 16 Warning 8 All Wheel Drive Switch 9 Clutch Cover Warning 9 Discretionary Warning 7 General Waming 6 Hitch Capacity Label 9 Rack Warning Front and Rear 9 Reverse Override Warning 9 Tire Pressure Load Warning 7 Safety Training 13 Service Interval Programming 51 Severe SS oss wait css an Gee 72 Side Panel Removal 92 Sidehilling 0 64 Signal Words 14 139 INDEX S Spark Arrestor 103 Spark Plug Inspection 100 101 Spark Plug Recommendations 100 Spark Plug Torque Specification 100 Spark Plugs 100 101 Specifications 128 129 Spri
16. Premium Fluid 8 0z 237 ml Coolant 2871323 60 40 Coolant gal 3 8 2871534 60 40 Coolant qt 95 Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium All Season Grease 3 0z 89 ml cartridge 2871423 Premium All Season Grease 14 0z 414 ml cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 0z 89 ml cartridge 2871551 Premium U Joint Lube 14 0z 414 ml cartridge 2871329 Dielectric Grease Nyogel 2872073 Chain Lube Aerosol 6 25 0z 185 ml 2872348 Chain Lube Aerosol 16 02 473 ml Additives Miscellaneous 2872889 Brake and Clutch Cleaner 2871326 Carbon Clean Plus 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2872893 Engine Degreaser 2871956 Loctite 565 Thread Sealant 2871076 Polaris Battery Tender Charger 127 SPECIFICATIONS Sportsman 450 Gross Vehicle Weight 1200 Ibs 544 kg Fuel Capacity 4 25 gal 16 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacity 2 7 qts 2 5 1 Front Rack Storage Box Capacity 90 Ibs 40 8 kg Rear Rack Storage Box Capacity 180 Ibs 81 6 kg Receiver Hitch Tongue Capacity 120 Ibs 54 kg Rear rack capacity and tongue weight not to exceed 180 Ibs 81 6 kg Receiver Hitch Towing Capacity 1225 Ibs 556 kg Overall Length 83 in 211 cm Overall Width 48 in 122 cm Overall Height 48 in
17. Tim State of G arge e Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 112 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 CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body first and the lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips e Avoid the use of harsh cleaners whic
18. activated Use the mode button to toggle through the diagnostic screens Clock Screen To reset the clock l 2 3 Enter the diagnostic mode Toggle to the clock screen Press and hold the mode button until the hour display flashes Release the button Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly When the desired hour is displayed wait approximately four sec onds until the minute display flashes When the display stops flashing the mode has been set Use the same procedure to reset the minutes 49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level Tachometer Screen View the tachometer to check engine speed AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil only on models with switchable AWD This screen is for informa tional purposes only Please see your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational purposes only Please see your dealer for all major repairs Programmable service interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds e
19. affect emissions M Have an authorized Polaris dealer perform these services A WARNING Improperly performing the procedures marked with a W could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services 73 MAINTENANCE Periodic Maintenance Chart 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 vake anusimnente as need 7 z ed See Pre Ride Checklist gt Front suspension Pre Ride on page 54 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 P 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 change coolant every 2 years gt ADC fluid Daily Check level daily add as ADC models needed Headlight taillight Daily Check operation apply worklight dielectric grease if replacing lamps gt Air filter Weekly Inspect replace as needed E main element Recoil housing Weekly D
20. 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 ANY 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 131 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 t
21. dealer for the correct replacement part 89 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes activated by moving the single brake lever toward the handlebar These brakes are self adjusting 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 A WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recommended level Do not overfill 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 38 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 brake pads when they are worn to 3 64 1 mm 5 Check the security and surface condition 3 64 1 mm of the disc Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 40
22. empty resevoir will result in trapped air If the level drops below the minimum line add fluid to the maximum line and repeat step 6 before proceeding 7 8 10 Torque the valves to 80 in lbs 9 Nm Reinstall the valve caps Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks Make sure the reservoir is free of debris Reinstall the cap securely Clean up any drips or spills 87 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 pres sure cap and into the radiator NOTE 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
23. from the exhaust system Use caution when traveling through tall grass especially dry grass A WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use 33 FEATURES AND CONTROLS Switches Worklight Headlight Switch Switch if equipped Main Key Switch Mode Reverse Override Engine Switch Stop Switch A WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional power while backing depress the override switch NOTE The override switch also allows activation of All Wheel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 46 34 FEATURES AND CONTROLS Switches Engine Stop Switch gt Move the stop switch either left oz or right to the OFF position to ii stop the engine quickly The OSN engine will not start or run when OFF RUN OFF the switch is off NOTE 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
24. heed the following warnings while servicing the spark arrestor could result in serious injury or death 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 Remove any combustible materials from the area Wear eye protection and leather work gloves Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s inclined Use the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrestor clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and release the throttle lever several times to purge carbon from the system Clean Out Plug 5 Ifcarbon comes out of the exhaust cover or plug the exhaust outlet Wear protective gloves 6 Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4 7 Ifparticles are still suspected to be in the muffler elevate the rear of the vehicle one foot 30 cm higher than the front Block the wheels 8 Place the transmission in PARK Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug a
25. ingested into the PVT system Use the following instructions to dry it out before operat ing 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 5 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 6 Test for belt slippage If the belt slips repeat the process 7 Take the vehicle to your dealer for service as soon as possible 106 MAINTENANCE Battery 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 Conventional 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 A WARNING Battery electrolyte is p
26. injury or death Always follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on 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
27. never exceed 10 mph 16 kph while towing a load on a level surface Vehicle speed should never exceed 5 mph 8 kph when towing loads in rough terrain while cornering or while ascending or descending a hill 59 OPERATION Driving Safely Driving Procedures XN BO SOS Da 60 Wear protective riding gear See page 10 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 OPERATION Driving Safely 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 technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at
28. placing a suitable stand under the footrest frame oS Remove the wheel nuts 7 Remove the wheel 93 MAINTENANCE Tires Wheel Installation A WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer 1 Place the transmission in PARK Lock the parking brake 3 Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation 4 Install the wheel nuts and finger tighten them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification 27 ft Ibs 37 Nm 90 ft Ibs 122 Nm Cast Aluminum Steel Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for maintenance service Nut Type Nut Torque Lug Nut 90 ft Ibs 122 Nm 2 Piece Flange Nut 27 ft lbs 37 Nm 94 MAINTENANCE Air Filter Pre Filter 1 Remove the seat Main Filter 2 Release the air box cover clips and remove the air box cover 3 Loosen the clamp and remove the filter 4 Remove the fabric type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main
29. return before starting the engine Also check occasionally during operation Engine speed and vehicle move ment are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns 4 9 to idle when the lever is released SA LI g This ATV is equipped with Polaris lt Electronic Throttle Control ETC Ba gt which is designed to reduce the risk hag 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 A WARNING Modifications to the ETC could result in failure to perform as designed which could result in severe injury or death Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms Always ensure that the throttle cable is properly installed to the ETC 36 FEATURES AND CONTROLS Brake Lever 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
30. shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 30 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals A WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Polaris Industries Inc or equivalent components designed for use on this ATV and should be installed and used according to approved instructions See your authorized Polaris ATV dealer for more information 31 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which
31. spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel 124 Engine Pings or Knocks Possible Cause TROUBLESHOOTING 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 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 Electronic throttle control malfunction See your dealer See your dealer Other mechanical failure Possible Lean Fuel Cause Low or contaminated fuel See your dealer Solution Add or change f
32. the lower oil deliv ery hose and remove the screen fitting from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape 10 Reinstall the screen fitting and rotate the fitting clockwise a mini mum of 2 1 2 turns into the tank threads Continue to rotate the fit ting until the nipple of the fitting aligns with the mark on the tank Alignment Mark NOTE Do not over tighten Maximum torque for the screen fitting is 25 ft Ibs 34 Nm 11 Reattach the oil line 80 MAINTENANCE Oil and Filter Change 12 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove it 13 Using a clean dry cloth clean the filter sealing surface on the crank case 14 Lubricate the o ring on the new filter with a film of fresh engine oil Check to make sure the o ring is in good condition 15 Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 17 Reinstall the drain plug Torque to 14 ft Ibs 19 Nm 18 Remove the dipstick 19 Add two quarts 1 9 1 of recommen
33. to start the engine See page 55 for starting pro cedures Worklight Switch Use the worklight switch if equipped to turn the worklight on or off The worklight is located at the rear of the vehicle Turn the light on while loading and unloading cargo in low light situations Turn the worklight off when driving Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position A WARNING Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness 35 FEATURES AND CONTROLS Throttle Lever A WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and
34. 00 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carbu retor can be adjusted 1 Start the engine and allow it to warm up for approximately five minutes Place the transmission in gear 3 Lock the parking brake 4 Turn the screw in clockwise to raise RPM Turn the screw out counterclockwise to lower RPM 121 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar 1 Locate the throttle cable adjuster at the handlebar 2 Squeeze the end of the rub N ber boot and slide it far enough to expose the end of the inline cable adjuster 3 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 NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut Boot 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Lock Nut Adjuster 122 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 66 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or use low range more frequently See page 106 Insufficient
35. 122 cm Wheelbase 50 5 in 128 3 cm Ground Clearance 11 in 28 cm Dry Weight 696 lbs 316 kg Minimum Turning Radius 65 in 165 cm unloaded Engine EHSOPLE Displacement 455 cc Bore x Stroke 87 9 x 75 Alternator Output 260 w Compression Ratio 9 8 1 Carburetor 34mm Mikuni Pilot Jet 42 5 Main Jet 167 5 Needle Jet P 6M 829 Jet Needle 41B33 3 Pilot Screw By flow taper 12 5 Brass Plug Ignition System Digital CDI Ignition Timing 30 2 5000 RPM Spark Plug Gap NGK BKRG6E 035 in 0 9 mm Lubrication System Dry Sump Driving System Type Automatic PVT Polaris Variable Transmission Front Suspension MacPherson strut with 8 2 21 cm travel Rear Suspension Progressive rate with 9 5 24 cm travel 128 SPECIFICATIONS Sportsman 450 Shift Type Side Lever H L N R P Gear Reduction Low 23 91 1 Gear Reduction Reverse 16 30 1 Gear Reduction Forward 10 49 1 Drive Ratio Front 3 82 1 Tires Pressure Front 25x8 12 5 psi Tires Pressure Rear 25x11 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 37 5 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument
36. 57 Consumer Product Safety 18 138 Cc Coolant Bottle 88 Coolant Radiator 89 Cooling System 88 89 Corrosion Removal Chrome 115 Crankcase Emission Control System 71 D Demand Drive Capacities 84 Disengaging Active Descent Control 45 Drive Belt Wear Burn 123 Drivetrain Break In 53 Driving Downhill 65 Driving in Reverse 69 Driving on a Sidehill 64 Driving on Slippery Surfaces 62 Driving Over Obstacles 68 Driving Procedures 60 Driving Safely 60 70 Driving Through Water 67 Driving Uphill 0 63 E Electromagnetic Interference 71 Emissions Limited Warranty 135 Engaging Active Descent Control 45 Engaging AWD 44 Engine Break In 53 Engine Fogging 117 Engine Idle RPM Adjustment 121 Engine Oil 78 79 Equipment Modifications 18 Exhaust Emission Control System 71 Eye Protection 11 F Fluid ADC ih a EE eae 86 87 Brakess c aeei ia ats 38 40 Demand Drive 84 85 Fluid Change ADG oF ic acsccheeesenare EE 87 Demand Drive 85 Foot Brake Auxiliary 40 Footwell Removal 92 Fuel Filter 0 ea eee ees 4 Fuel Recommendations 41 Fuel Safety 0 0 0 0
37. AFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV on public streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways A WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants 21 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balance and perception could be affected Consuming alcohol and or drugs before or while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HA
38. M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Engine oil change 100 H 6M 1000 1600 Perform a break in oil change at one month gt Oil filter change 100 H 6M 1000 1600 Replace with oil change z 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 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 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc 75 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km 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 E ADC fluid 200 H 24M 2000 3200 Change every two years ADC models
39. N A caution indicates a situation that may result in damage to the vehicle NOTE A note will alert you to important information or instructions 14 SAFETY Operator Safety A WARNING Serious injury or death can result if you do not follow these instructions and procedures which are outlined in further detail within your owner s manual Read this manual and all labels carefully and follow the operating procedures described Never operate an ATV without proper instruction Take a training course Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on enrollment in the ATV RiderCourse Never allow anyone under 16 years of age to operate this ATV Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course Always avoid operating an ATV on paved surfaces including side walks driveways parking lots and streets Never operate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating an ATV Never oper
40. Polaris ADC Fluid See page 127 for the part numbers of Polaris products NOTE Do not use brake fluid Brake fluid will damage rubber components in the hydraulic system 1 Open the front box cover and pull open the access door View the fluid level in the reservoir 3 Ifthe level is below the minimum mark remove the cap and add the recommended fluid 4 Reinstall the cap Secure the access door Secure the box cover ADC Fluid Reservoir 86 MAINTENANCE Active Descent Control ADC Fluid Fluid Change l 2 Position the vehicle on a level surface Before performing the fluid change allow the vehicle to sit for at least 30 minutes Thoroughly clean the areas around and on the ADC reservoir and bleeder valves one on each side of the differential Remove the reservoir cap and diaphragm assembly Use a shop towel or suction tool to remove debris from the fluid and reservoir NOTE Debris in the reservoir may result in inadequate bleeding and reduced performance of the system Fill the reservoir to the maximum line with fresh ADC fluid Remove the protective caps from the bleeder valves Slowly loosen one of the valves turn counter clockwise and allow fluid and trapped air to flow from the fitting Close the valve when clean fluid begins to flow Repeat this step for the remaining valve IMPORTANT Close the bleeder valves before the reservoir fluid level drops below the minimum fill line Adding fluid to an
41. The throttle is open throttle is applied The transmission is shifted to neutral or park 45 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 dis tance in miles as well as hours of operation It also includes a reverse speed limiter function that limits the ATV s speed to approximately 7 9 mph Refer to page 34 for additional information Speedometer Needle Speedometer Rider P amp LARIS Information Center NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Do not allow insect sprays to contact the lens Immediately clean off any gasoline that splashes on the instrument cluster 46 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 2 5 seconds at start up NOTE Ifthe instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electr
42. ZARD Never consume alcohol or drugs before or while operating an ATV A WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Q a 30 f fao Excessive speed increases the operator s 10 SA 0 so chance of losing control of the ATV which S can result in an accident causing severe X iy D a injury or death _N Le HOW TO AVOID THE HAZARD j Always operate the ATV at a speed that s proper for the terrain visibility and operating conditions and your experience 22 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving ss A WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules described in the owner s manual 23 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests durin
43. ach time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance See page 51 NOTE The service interval is programmed at 50 hours at the factory 50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for about 7 seconds until either ON or OFF appears in the Rider Information Center depending on your preference To reset the service interval 1 Enter the diagnostic mode 2 Toggle to the service interval screen 3 Press and hold the mode button for 2 3 seconds until the wrench icon flashes Release the button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly NOTE If you scroll past the intended number press and hold the button until the hours cycle back to zero 5 When the desired setting is displayed wait until the wrench icon stops flashing The new service interval is now programmed Miles Kilometers toggle The display in the tripmeter and odometer can be changed to display either standard or metric units of measurement 1 Enter the diagnostic mode 2 Toggle to the screen that displays either kilometers KM or miles MP 3 Press and hold the mo
44. ar bolts 3 Adjust the handlebar to the desired height NOTE Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft Ibs 14 17 Nm then Handlebar torque the rear two bolts A Bolts gap of up to 1 8 3 mm will remain at the rear of the clamp blocks 120 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 NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area NOTE Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers Carburetor Engine Idle RPM Adjustment Recommended engine idle RPM is 12
45. arting the engine NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 102 Have the vehicle serviced by your dealer at the first opportunity 67 OPERATION Driving Safely Driving Over Obstacles Be alert Look ahead and learn to read the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches A WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain 68 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at sharp angles 6 Never open the throttle suddenly A WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reve
46. at 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 or after 5000 km 3100 miles whichever comes first This emission related warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas 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
47. ate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience Never attempt wheelies jumps or other stunts Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and schedules outlined in your owner s manual Always keep both hands on the handlebars and both feet on the foot rests of the ATV during operation 15 SAFETY Operator Safety 16 Always travel slowly and use extra caution when operating on unfa miliar terrain Be alert to changing terrain conditions Never operate on excessively rough slippery or loose terrain Always follow proper turning procedures as described in this manual Practice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speeds Always have the ATV inspected by an authorized Polaris dealer if it s been involved in an accident Never operate on hills too steep for the ATV or for your abilities Practice on smaller hills before attempting larger hills Always follow proper procedures for climbing hills Check the terrain carefully before ascending a hill Never climb hills with excessively slippery or loose surfaces Shift your weight uphill Never open the throttle suddenly or make sudden gear changes Never go over the top of a hill at high speed Always follow proper procedures for going downhill an
48. ating the ATV through deep or fast flowing water If it s unavoidable travel slowly balance your weight carefully avoid sud den movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test the brakes after leaving water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper installation or use of acces sories Never exceed the stated load capacity for your ATV Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for carrying cargo or towing Allow a greater distance for braking 17 SAFETY Operator Safety FOR MORE INFORMATION ABOUT ATV SAFETY call the Consumer Product Safety Commission at 1 800 638 2772 or visit www cpsc gov visit www atvsafety org or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed o
49. ble or dismount on the uphill side immediately 64 OPERATION Driving Safely Driving Downhill A WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious injury or death Apply the brakes gradually When driving downhill follow these precautions l 2 3 4 5 If your ATV is equipped with Active Descent Control always engage AWD before descending a hill See page 45 Shift your weight uphill Drive straight downhill Slow down Squeeze the brake lever gradually NOTE Before operating your ATV learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable 65 OPERATION Driving Safely 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 66 Stop and lock the parking brake while keeping body weight uphill If your ATV is equipped with Active Descent Control engage AWD See page 45 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 loc
50. cause serious burns to skin Allow lamps to cool before servicing Headlight Lamp Replacement 1 Remove the two screws on the lower front corners of the headlight pod Remove the screw from the rear of the pod 3 Lift the pod slightly while depressing the tabs at the rear of the pod Lift the pod cover and disconnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod 96 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 25 ft 7 6 m 1 Position the vehicle on a level surface with the headlight approxi mately 25 ft 7 6 m from a wall Place the transmission in PARK 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side
51. could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer A WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water 32 SAFETY Operator Safety A WARNING Operating a damaged ATV can result in an accident with serious injury or death After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering systems A WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death A WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away
52. d for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight uphill Never attempt to turn the ATV around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braking described in this manual Always dismount on the uphill side or to either side if the ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in this manual SAFETY Operator Safety Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow proper procedures when operating over obstacles as described in this manual Always be careful of skidding or sliding On slippery surfaces like ice travel slowly and use extra caution to reduce the chance of skid ding or sliding out of control Avoid oper
53. de button until the letters flash then press and release the button once When the display stops flashing the mode has been set 51 OPERATION Fuel Safety A WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline Always refuel with the engine stopped and outdoors or in a well ventilated area Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked A WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ventilated areas 52 OPERATION Break In Period The break in period for your new Polaris ATV is the first ten hours of operation or the time it takes to use the first two full tanks of gasoline No single action on your part is as important as following the proce dures for a proper break in Careful treatment of a new engine and drive components wi
54. ded oil Reinstall the dipstick NOTE Ifthe sump is not drained add about 1 3 4 quarts 1 6 I initially 20 Place the transmission in PARK 21 Lock the parking brake 22 Prime the oil pump using the procedure on page 82 Then stop the engine and inspect for leaks 23 Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick 24 Dispose of used filter and oil properly 81 MAINTENANCE Oil and Filter Change Oil Pump Priming This priming procedure must be s Tank performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected 1 Clamp or pinch off the vent line approximately 2 5 cm from the oil tank between the end of the oil tank vent fitting and the sae gt Pressure vent line s pressure relief slit Relief Slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation NOTE If you do not hear air the line has not bled Repeat the priming proce dure 82 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 72 Maintain the oil level at the bottom of the fill plug hole threads We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant See page 127 for
55. e of the hill 26 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Traveling downhill improperly WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 65 Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral If your ATV is equipped with Active Descent Control always engage AWD before descending a hill See page 45 Always check the terrain carefully before descending a hill Shift your weight rearward 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 A WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning on hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 66 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as descr
56. e 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 133 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be denied Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for 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 1 763 417 8650 Canada 1 204 925 7100 134 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 th
57. e the piston to BDC and pour two ounces 59 ml of Premium 4 Synthetic 0W40 engine oil into the cylinder 3 Reinstall the spark plug Torque to specification 4 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 5 Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 Treat the fuel system with Polaris Carbon Clean See page 116 7 IfPolaris fuel system additive is not used the fuel tank fuel lines and carburetor should be completely drained of gasoline 8 To eliminate any fuel remaining in the carburetor run the engine until it stops 117 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 72 Battery Storage See pages 110 111 for storage and charging procedures Storage Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory o
58. er 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 in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage 130 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
59. erious burns Wear protective gloves when removing a spark plug for inspection 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation 100 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect car buretion 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 Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi tions Drain the housing before storing the vehicle Make sure the hous ing is completely dry before reinstalling the drain plug 1 Stop the engine 2 Place the transmission in gear 3 Lock the parki
60. f unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual A WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skidding or sliding out of control 29 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating the ATV through deep or fast flowing water WHAT CAN HAPPEN Tires may float causing loss of traction and loss of control which could lead to an accident or overturn HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 67 travel slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads A WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or person resulting in severe injury HOW TO AVOID THE HAZARD Before
61. faster speeds A WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury Avoid turning at sharp angles Never turn at high speeds 61 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freez ing weather follow these precautions 1 Slow down when enter ing slippery areas 2 Engage AWD before wheels begin to lose traction 3 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction A WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excessively slippery surfaces Always reduce speed and use additional caution 62 OPERATION Driving Safely Driving Uphill 25 Maximum Whenever traveling uphill follow these precautions l PE Ne a S If your ATV is equipped w
62. filter NOTE Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur Breather Filter 7 Reinstall the air box cover and the seat Breather Filter Hose The breather filter is on the hose that runs between the engine and air box See illustration above 1 Remove the left side panel See page 92 2 Remove the hose clamps from the filter and pull the filter out of the hoses 3 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 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and hose clamps NOTE The filter is effective with the arrow pointing in either direction CAUTION Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filter after removing it for service 95 MAINTENANCE Lights When servicing a halogen lamp don t touch the lamp with bare fingers Oil from your skin leaves a residue causing a hot spot that will shorten the life of the lamp A WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the headlights frequently to maintain lighting quality Hot components can
63. g operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation A WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions 24 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough slippery or loose terrain WHAT CAN HAPPEN Operating on excessively rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain A WARNING POTENTIAL HAZARD T
64. gage the side panel from the grommet 3 Pull the panel downward and rearward to remove it Step 1 Footwell Removal 1 Remove the four screws on the bottom of the footwell 2 Usea flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell 92 MAINTENANCE Tires Refer to the specifications section beginning on page 128 for recom mended tire type size and pressure A WARNING Operating your ATV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less Tire Tread Depth Always replace tires 1 8 3 mm t when tread depth is A worn to 1 8 3 mm or less tp WS 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 Wheel Removal Stop the engine Place the transmission in PARK Lock the parking brake Loosen the wheel nuts slightly Ae E aie a TE Elevate the side of the vehicle by
65. h can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish 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 113 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 Transmission seals e Brakes e Cab and body panels e Labels and decals NOTE If warning and safety labels are damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle 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 114 MAINTENANCE Cleaning and Storage Chrome Wheel Ca
66. h 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 See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution Debris lodged in screen Remove and clean the screen Pull on the top portion of the screen then remove the lower portion Plugged Radiator Use a garden hose to flush any debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiency Obstructed cooling fan Clean any debris or mud that may be interfering with fan movement 126 POLARIS PRODUCTS B Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2871281 Premium 4 Synthetic OW 40 4 Cycle Engine Oil qt 95 I 2871844 Premium 4 Synthetic OW 40 4 Cycle Engine Oil gal 3 8 I Gearcase Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 I 2873603 Premium AGL Synthetic Gearcase Lube gal 3 8 2876144 Active Descent Control ADC Fluid 2871653 Premium ATV Angle Drive Fluid 8 0z 237 ml 2872276 Premium ATV Angle Drive Fluid 2 5 gal 9 5 I 2870465 Pump for Gallon 3 8 I Jug 2876251 Demand Drive LT
67. he dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the above terms are void because of state or federal law all other warranty terms will remain in effect Engine Oil 1 Mixing oil brands or using non recommended oil may cause engine damage We 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 132 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 Po
68. ibed in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the ATV 27 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Stalling rolling backwards or improperly dismounting while climbing a hill WHAT CAN HAPPEN The vehicle could overturn HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill If your ATV is equipped with Active Descent Control always engage AWD before ascending a hill See page 45 If all forward speed is lost Keep your weight uphill Apply the brakes Lock the parking brake when fully stopped If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure described in the owner s manual See page 66 28 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible I
69. il rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine Recoil Starter Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not extend the starter rope so far that it stops If the starter rope handle is not seated properly water may enter the recoil housing and damage components Make sure the handle is fully seated on the recoil housing especially when traveling in wet areas 43 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 iS AWD drive and the AWD indicator light Switch in the instrument cluster will be on When in AWD the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 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
70. ilter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to clean the fuel filter 41 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear Gear selector is located on the Selector aoe side of the vehicle High Gear Low Gear V ass Neutral Reverse Park Joa the ATV is left unattended always place the transmission in PARK and lock the parking brake YAZET CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 42 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start Handle the engine use the recoil starter Follow the starting procedures on page 55 cranking the engine with the recoil starter instead of the main key switch 1 Grasp the recoil starter rope handle tightly 2 Pull slowly so you can feel the engine strokes NOTE The rope will be harder to pull when the engine is on a compression stroke When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 3 Allow the reco
71. in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS IF OWNER S MANUAL IS MISSING CONTACT A POLARIS DEALER FOR A REPLACEMENT SAFETY Safety Decals and Locations Discretionary Tire Pressure Load Warning Se Warning Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To pre vent flip over on hilly terrain when going up or down use throttle and brakes gradually REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sudden braking or sharp turns e Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle e When this ATV is not in operation or unattended place shift in the park posi tion Tire Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 1200 LBS 545 kg Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured
72. ires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecft Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the recoil cover or stator housing Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 This vehicle complies with European directives 97 24 EC and 89 336 EEC 71 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 Ins
73. ith Active Descent Control always engage AWD before ascending a hill See page 45 Drive straight uphill Avoid steep hills 25 maximum Keep both feet on the footrests Shift your weight uphill Proceed at a steady rate of speed and throttle opening Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle A WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual 63 OPERATION Driving Safely Driving on a Sidehill Sidehilling A WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual Sidehilling can be dangerous and should be avoided if at all possible If you encounter a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Shift your weight uphill 3 Keep your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE Ifthe vehicle begins to tip quickly turn the front wheel downhill if pos si
74. jury or death could result Always inspect the vehicle before each use to ensure it s in protective clothing Item Remarks Page Brake system lever travel Ensure proper operation H Brake fluid Ensure proper level 38 Auxiliary brake Ensure proper operation 40 Front suspension Inspect lubricate if necessary 77 Rear suspension Inspect lubricate if necessary 77 Steering Ensure free operation Tires Inspect condition and pressure 93 Wheels fasteners Inspect ensure fastener tightness an Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels a Coolant level if applicable Ensure proper level ee Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation o Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pre filter Inspect clean 95 Air box sediment tube Drain deposits whenever visible Headlamp Check operation apply Polaris dielec 35 tric grease when lamp is replaced 96 Brake light taillight Check operation apply Polaris dielec 99 tric grease when lamp is replaced Riding gear Wear approved helmet goggles and 10 54 OPERATION Starting the Engine A WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area 1 Positi
75. k 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 Safely Driving Through Water Your ATV can operate through water with a maximum recom mended depth equal to the bot tom of the footrests Follow these procedures when operat ing through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as out lined in the maintenance chart See page 72 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart If your vehicle becomes immersed or is operated in water that exceeds the footrest level take it to your dealer for service before st
76. l weather driving can indicate contaminants such as gas or moisture col lecting in the crankcase If the oil level is over the full safe mark change the oil immedi Que ately Dipstick 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle Safe Range for 20 30 seconds Stop the Ai engine C 3 Remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick com pletely 5 Remove the dipstick and check the oil level Maintain the oil level in the safe range Do not overfill Add Oil Safe 79 MAINTENANCE Oil and Filter Change A CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 72 Always change the oil filter whenever changing oil 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 Place a drain pan under the oil tank SP Screen Fitting i 6 Remove the drain plug Allow 7 the oil to drain completely 3 7 Install a new sealing washer on the drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft Ibs 19 23 Nm 9 Disconnect
77. laris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warranty or service bulletin coverage if you have any questions This policy does not apply to vehicles registered to government officials or military per sonnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Recalls How to Get Service In the Country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move Vehicles importation rules vary considerably from country to country You may b
78. ld result in an accident and serious injury or death Always check to be sure the parking brake is disengaged before operating Locking the Parking Brake l 2 Place the transmission in PARK Squeeze and release the brake lever two or three times then squeeze and hold Push the parking brake lock forward to engage the lock Release the brake lever To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling 39 FEATURES AND CONTROLS Auxiliary Foot Brake 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 NOTE Since this is a rear brake only it will not be as effective as the all wheel single lever system A WARNING 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 auxilia
79. ll result in more efficient performance and longer life for these components CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 41 2 Check the oil level on the dipstick See page 79 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 levels controls and areas outlined on the daily pre ride inspection checklist See page 54 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation dur ing the break in period 53 OPERATION Pre Ride Checklist A WARNING proper operating condition If a proper inspection is not done before each use severe in
80. low the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child eh under the minimum age recommendation operates an ATV lt 1 6 Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could be susceptible to accident or injury HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV 19 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Carrying a passenger on an ATV WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers A WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops 20 S
81. lt Improper break in Always break in a new belt and or clutch See page 53 123 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Tripped circuit breaker Solution Reset the breaker 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 Clogged fuel valve or filter Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fuel valve is turned off Turn the fuel valve on Fouled or defective spark plug s No spark to spark plug Inspect plugs and replace if necessary Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs 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 plugs 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
82. mbly away from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Worklight if equipped Lamp Replacement 1 Remove the harness connector from the back of the light Connector assembly lt L 2 Turn the lamp counterclock wise to remove it S YS af 3 Apply dielectric grease to the X ER on socket and install the new N La lamp 4 Reinstall the harness connector 5 Test the light for proper operation 99 MAINTENANCE Spark Plugs Spark Plug Recommendations CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Refer to the specifications section beginning on page 128 for the recom mended spark plug type and gap for your vehicle Torque spark plugs to specification 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 101 A WARNING A hot exhaust system and engine can cause s
83. mmended See page 113 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 NOTE Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust sys tems 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 80 Air Filter Air Box l D pet and clean or replace the pre cleaner and air filter See page 5 2 Clean the air box 3 Drain the sediment tube 4 Clean or replace the breather filter See page 95 Recoil Housing Drain the recoil housing See page 101 116 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 72 e Demand drive unit front gearcase e ADC fluid ADC models change every two years e Rear gearcase if equipped Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength fill Fog the Engine 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove the spark plug Rotat
84. nd remove the exhaust outlet cover or plug 103 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 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 Always make sure the PVT housing is securely in place during operation 104 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements As engine speed increases the force exerted on the movable drive sheave by the flyweights also increases This in turn increases the amount of pinch applied to the drive belt Similarly if the engine speed decreases the amount of cen trifugal force decreases
85. ng Adjustment Rear Shock 120 Starting the Engine 55 56 Steering Assembly 92 Storage wee we Bsn ee ats 113 118 Storage Tips 116 118 Switches AWD Switch 44 Engine Stop Switch 35 Headlight Switch 35 Main Key Switch 35 Mode Reverse Override Switch 34 Worklight Switch 35 T Taillight Lamp Replacement 99 Throttle Cable Freeplay Adjustment 122 Throttle Lever 36 Tire Tread Depth 93 Tires Wheel Installation 94 Wheel Nut Torque 94 Wheel Removal 93 140 T Toe Alignment 91 Towing Loads 58 Tram voiced eee tea seein 13 Transmission 42 Transmission Oil 83 84 Transporting the ATV 119 Turning Around ona Hill 66 Turning the Vehicle 61 V Vehicle Identification Numbers 5 Vehicle Immersion 102 MINS S shed etre alge at R 5 Ww Warning Symbols 14 Washing the Vehicle 113 114 Wheel Hub Tightening 93 Wheel Installation 94 Wheel Nut Torque Specifications 94 Wheel Removal 93 Worklight Lamp Replacement 99 Worklight Switch 35
86. ng brake 4 Remove the drain screw on the bottom of the recoil housing 5 Reinstall the drain screw NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crank case drain is opened 101 MAINTENANCE Vehicle Immersion CAUTION If your vehicle becomes immersed major engine damage can result if the machine is not thoroughly inspected Take the vehicle to your dealer before starting the engine 10 11 12 13 102 If it s impossible to take your ATV to a dealer before starting it fol low the steps outlined below Move the ATV to dry land or at the very least to water below the footrests Check the air box If water is present dry the air box and replace the filter with a new filter Turn the fuel valve off Remove the spark plug Loosen the carburetor drain screw Turn the engine over several times using the electric start Dry the spark plug Reinstall the plug or install a new plug Tighten the carburetor drain screw Turn the fuel valve on Drain Screw Attempt to start the engine If necessary repeat the drying pro cedure 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 the procedure on page 106 for drying out the PVT MAINTENANCE Spark Arrestor A WARNING Failure to
87. nsure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each month during storage and recharge as needed to maintain a full charge NOTE Power plug leads may need to be bent down so that the battery cover can be installed NOTE Battery charge can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 127 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery r i hee 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 110 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 108 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 109 Make sure the positive terminal is toward the front of the vehicle Battery Charging Sealed Battery The following ba
88. of the headlight pod Adjust the beam to the desired position by turning the knob either clockwise or counterclockwise Low Beam Adjustment Phillips Screw The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located a 2 Tilt the headlamp upward or at the rear of the headlamp L downward 3 Tighten the screw i ee on Bey Zor ay LR MAINTENANCE Lights Headlight Housing Replacement 1 Remove the two screws on the lower front corners of the headlight pod Lift the pod slightly while depressing the tabs at the rear of the pod 3 Lift the pod cover and disconnect the speedometer harnesses from the speedometer 4 Unplug the headlamp from the wiring harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the head lamp parting line to the end of the adjustment knob stop is 5 1 8 13 cm 10 Adjust the headlight aim by turning the adjusting knob 98 MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counterclockwise and pull the harness asse
89. oisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteries produce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN 107 MAINTENANCE Battery A WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last Battery Removal Disconnect the battery hold down strap Remove the battery cover On conventional batteries remove the battery vent tube Disconnect the black negative battery cable first Disconnect the red positive battery cable last OYE eS NO Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte CAUTION If electrolyte spills immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle
90. om right side of the unit Fill Level Drain Plug Demand Drive Capacities Sportsman 450 9 oz 265 ml 84 MAINTENANCE Front Gearcase Demand Drive Fluid Fluid Check l 2 3 Position the vehicle on a level surface Remove the fill plug Check the fluid level Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Fluid Change l 2 3 Position the vehicle on a level surface Remove the fill plug Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to 11 ft Ibs 15 Nm Add the recommended fluid See page 84 for capacity Maintain the fluid level at the bottom of the fill hole threads Reinstall the fill plug Torque to 8 10 ft Ibs 11 14 Nm Check for leaks Dispose of used fluid properly 85 MAINTENANCE Active Descent Control ADC Fluid If your vehicle is equipped with Active Descent Control there are two fluid levels that must be maintained demand drive fluid and ADC fluid See page 84 for demand drive fluid maintenance Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 72 Maintain the fluid level between the minimum and maximum marks on the reservoir We recom mend the use of
91. on the vehicle on a level surface 2 Place the transmission in PARK 3 Lock the parking brake NOTE The starter interlock will prevent the engine from starting if the trans mission is in gear and the brake is not engaged 4 Turn the fuel valve on 5 Sit on the vehicle NOTE Do not use the choke if starting a warm engine Excessive use of the choke can cause the spark plug to become wet fouled 6 Ifthe engine is cold pull the choke knob out until it stops NOTE The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off dur ing operation as excess fuel washing into the engine oil will increase wear on engine components Tension NOTE If the knob doesn t stay Adjusting Nut where positioned increase the tension by rotating the tension adjusting nut clockwise 7 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine 55 OPERATION Starting the Engine 8 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the engine starts 9 Ifthe 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 necessa
92. onic speedometer If this occurs take the ATV to your Polaris dealer for proper diagnosis 1 Gear Indicator This 3 4 5 6 7 indicator displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park 2 AWD Indicator This indicator illuminates when the AWD switch 1 is in the AWD position 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also occur when the engine is at idle and high elec trical load lights cooling fan accessories is applied Drive at a higher RPM or recharge the battery to clear the warning 6 Odometer Tachometer Tripmeter Hour Meter Clock 7 Fuel Gauge The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments will flash FUEL will display in the LCD and the speedometer needle will blink Refuel immediately 8 Check Engine Warning Indicator The word HOT displays if the engine overheats Do not operate the ATV if this warning appears Serious engine damage could result 9 Mode Indicator 47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options The reverse override button is also the MODE button See page 34
93. our eligible family members who will be riding the ATV to take the ATV RiderCourses You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV 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 vehicle are thoroughly inspected at specific intervals 13 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle Your safety is involved when these words and sym bols are used Become familiar with their meanings before reading the manual A The safety alert symbol on your vehicle or in this manual alerts you to the potential for injury A WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death A CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTIO
94. page 127 for the part numbers of Polaris products NOTE Always follow the manufacturer s mixing recommendations for the freeze protection required in your area Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle PA bom 1 Remove the left side panel See page 92 ea 2 Maintain the coolant level between the minimum and maximum marks on the bot tle when the fluid is cool 3 Add coolant as needed O P 88 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 A WARNING Escaping steam can cause severe burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover and pull open the access door Remove the pressure cap 3 Using a funnel slowly add coolant through the radia tor filler neck 4 Reinstall the pressure cap 5 Secure the access door 6 Secure the box cover Radiator Cap NOTE Use of anon standard pressure cap will not allow the recovery system to function properly Contact your
95. pect 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 136 NOTE Service and adjustments are important for proper vehicle operation If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition 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 the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 72 MAINTENANCE Periodic Maintenance Chart 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
96. r power of the vehicle or make any other modifications to the vehicle for these purposes Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle 18 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating this ATV without proper instruction WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCourse offered by Polaris through the SVIA They should then regularly practice the skills learned in the course and the operating techniques described in the Owner s Manual For more information about the ATV RiderCourses contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org A WARNING POTENTIAL HAZARD Failure to fol
97. rain water as needed check often if operating in wet conditions gt Brake pad wear 10H Monthly 100 160 Inspect periodically a Battery 20H Monthly 200 320 Check terminals clean test gt Demand drive fluid 25 H Monthly 250 400 Inspect level change yearly gt Rear 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 Perform these procedures more often for vehicles subjected to severe use E Emission Related Service m Have an authorized Polaris dealer perform these services 74 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt General 50H 3M 500 800 Lubricate all fittings pivots lubrication cables etc Carburetor float 50H 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 6
98. re if equipped Proper maintenance will protect chrome wheels from corrosion pre serve wheel life and ensure a like new appearance for many years NOTE Chrome wheels exposed to road salt or salt in the air in coastal areas are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements 1 Wash chrome wheels frequently Use a mild detergent Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the product labels and instructions Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as out lined above 115 MAINTENANCE Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make any necessary repairs and clean the vehicle as reco
99. rol or forward flipover may result especially in AWD See Owner s Manual All Wheel Drive Switch Do not push switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual Hitch Capacity Label TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 120 LBS 55 KG SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injury Eye Protection Gloves Long Pants 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 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 10 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
100. rse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles NOTE Your Polaris ATV is equipped with a reverse speed limiter Use the override button with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage Operate the throttle just enough to maintain a desired speed 69 OPERATION Driving Safely 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 PARK Lock the parking brake Always block the rear wheels on the downhill side Turn the fuel valve off is 70 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100 1C Fed eral law requ
101. ry Repeat this procedure until the engine starts NOTE Ifa warm engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out may be nec essary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again 10 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in CAUTION Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehicle 56 OPERATION 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 for engine heater kits which provide quicker warm ups and easier starting in colder weather 57 OPERATION Hauling Cargo Your ATV has been designed to carry or to
102. ry brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary foot brake is located Auxiliary Foot Brake on the inside of the right footrest Operate this brake with your right foot NOTE Ifthe rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels with out skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located near the auxiliary brake Maintain the fluid level between the maximum and minimum marks 40 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine Refer to the engine starting procedure on page 55 for correct choke and throttle settings during start ing Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well OFF For vehicle storage and when transporting RES For normal operation ON Not used on this model NOTE This vehicle is equipped with a digital fuel gauge that will S indicate a low fuel condition Refuel when the gauge indi OFF cates a low fuel condition Fuel ON Fuel Tank Cap 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 Filter The in line fuel f
103. 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 Decals and Locations Warning decals have been placed on the ATV for your protection Read and follow the instructions of the decals on the ATV carefully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off contact your Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part number is printed on the decal General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle 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
104. 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 on the right side of the gearcase on the right side of the ATV behind the wheel well S Fill Plug Oil Check 1 Position the vehicle on a level surface 2 Remove the fill plug Check the oil level 4 Reinstall the fill plug Torque to 22 ft Ibs 30 Nm 5 Reinstall the footwell Ww 83 MAINTENANCE Transmission Oil Oil Change 1 Remove the fill plug 2 Place a drain pan under the gearcase 3 Remove the drain plug Allow the oil to drain com pletely 4 Clean and reinstall the drain plug Torque to 22 ft Ibs 30 Nm Add 32 oz 948 ml of the recommended oil Reinstall the fill plug Torque to 22 ft lbs 30 Nm Check for leaks Dispose of used oil properly BO esl SON Front Gearcase Demand Drive Fluid Always check and change the demand drive fluid at the intervals out lined in the Periodic Maintenance Chart beginning on page 72 We rec ommend the use of Demand Drive LT Premium Fluid Use of other fluids may result in improper operation of components See page 127 for the part numbers of Polaris products Maintain the fluid level at Fill the bottom of the fill hole threads See below for capacity The fill plug is located on the right side of the demand drive unit The drain plug is located on the bott
105. to the racks With dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information SAFETY Safety Decals and Locations Rack Age 16 Warning Warning Rack Warning Warning No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH 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 SAFETY Safety Decals and Locations Clutch Cover Warning WARNING NO STEP e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death 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 90 Ibs 41 kg Rear 180 Ibs 82 kg Reverse Override Warning WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of cont
106. ttery 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 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 A 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 For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charger refer to the charger manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 111 MAINTENANCE Battery Battery Charging Sealed Battery NOTE Always verify battery condition before and 1 2 hours after the end of charging harge
107. tween 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 2007 Sportsman 450 Owner s Manual P N 9920629 2 TABLE OF CONTENTS Know Your Vehicle 0000 00 ee eens 5 Safety 44 40 erie eet SS eee ee mast seals 6 Features and Controls 2 006 34 Operation ice 2 23 eed eee ere ie eins 52 Emission Control Systems 71 Maintenance 000 eee eee eee 72 Adjustments 2220002e cece eee 120 Troubleshooting 0200e eee eee 123 Polaris Products 2 3 cceewed sence eek es 127 Specifications 2 fic ccs eee sees lee 128 Warranty eer Siete n Gd ATOR eRe ee es 130 Maintenance Log 000eeees 136 INDOX viet ee ee eee tee eae ae 138 KNOW YOUR VEHICLE As the operator of the vehicle you are responsible for your personal safety the safety of others and the protection of our environment Read and understand your owner s manual which includes valuable informa tion about all aspects of your vehicle including safe operating proce dures Vehicle Identification Numbers Record your vehicle s identification numbers and key number in the spaces provided Remove the spare key and
108. uel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Replace with recommended fuel Incorrect jetting Possible Rich Fuel Cause Fuel is very high octane See your Polaris dealer Solution Replace with lower octane fuel Overuse of choke Inspect clean and or replace spark plugs Stopping starting without adequate warm up Allow engine to warm up before operat ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Incorrect jetting See your Polaris dealer 125 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Overuse of choke Inspect clean and or replace spark plugs Water is present in fuel Replace with new fuel 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 fres
109. ure washing or submerg ing Front Prop Shaft Yoke 77 MAINTENANCE Engine Oil Oil Recommendations Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines It s a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection See page 127 for the part num bers of Polaris products Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambi ent temperatures from 40 F to 120 F 40 to 49 C Its excep tional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s OW 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient tem perature operation CAUTION Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium 4 synthetic oil or another OW 40 API certified SH oil Never substitute or mix oil brands 78 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV NOTE Arising oil level between checks in coo
110. urning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for turning as described in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed 25 SAFETY Operator Safety A WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25 degrees A WARNING POTENTIAL HAZARD Climbing hills improperly WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual If your ATV is equipped with Active Descent Control always engage AWD before ascending a hill See page 45 Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25 degrees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other sid
111. utlets 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 118 Transporting the ATV Follow these procedures when transporting the vehicle MAINTENANCE 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Secure the fuel cap oil cap and seat 5 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 6 Remove the key to prevent loss during transporting 119 ADJUSTMENTS Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer Handlebars The handlebars can be adjusted for rider preference A WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Remove the upper headlight pod 2 Loosen the four handleb
112. w a certain amount of load Always read and understand the load distribution warning labels on the vehicle and never exceed the weight capacities outlined in the specifi cations section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combina tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity CAUTION Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 6 3 4 17 cm can result in serious damage to the vehicle and will void your ATV warranty Never install a hitch longer than 6 3 4 17 cm Never install automotive accessories on your Polaris ATV Always install Polaris approved or equivalent accessories designed for ATV use 58 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
113. warm up at low ambient tempera tures Warm the engine at least 5 minutes 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 Utility use plowing Use low range only Stuck in mud or snow Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Belt slippage from water or snow ingestion into the PVT system Dry out the PVT See page 106 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 for one mile 5 miles or more when temperature is below freezing Wrong or missing belt Install the recommended be

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