Polaris Offroad Vehicle 2005 Sportsman 800 EFI User Manual

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Part No. 9917720 Rev 01

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WARNING

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.

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based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor

discrepancies may result between the actual vehicle and the information presented in this

publication. Depictions and/or procedures in this publication are intended for reference

use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or

reuse of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2005 Sportsman 800 EFI Owner’s Manual P/N 9917720

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our

world-wide family of Polaris owners. We proudly produce an exciting

line of utility and recreational products.

Polaris Recreational Vehicles

S Snowmobiles

S All-terrain vehicles (ATVs)

S Watercraft

S RANGER utility vehicles

S Victory motorcycles

We believe Polaris sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your Polaris vehicle, making it the finest machine we’ve ever

produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your

manual contains instructions for minor maintenance, but information

about major repairs is outlined in the Polaris Service Manual and

should be performed only by a Factory Certified Master Service Dealer

(MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

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

products, available through our online store at www.purepolaris.com.

Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of

Polaris Industries Inc.

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VEHICLE IDENTIFICATION NUMBERS

Record your ATV’s identification numbers and key number in the

spaces provided. Remove the spare key and store it in a safe place.

Your key can be duplicated only by mating a Polaris key blank with

one of your existing keys, so if both keys are lost, the ignition switch

must be replaced.

31XX

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2):

Key Number (3):

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TABLE OF CONTENTS

WELCOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . 4

SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . 32

OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . . . . . . 63

MAINTENANCE AND LUBRICATION . . . . . . . . . . . . . . . . 64

ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

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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.

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:

ALWAYS:

7172560

WARNING

7172561

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SAFETY

Safety Decals and Locations

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 to the racks. With

dual racks, load distribution 1/3 front 2/3 rear is best. For stability

on rough or hilly terrain, reduce speed and cargo. Do not block

headlight. Be careful if load extends over the side of the rack.

Read Owner’s Manual for more detailed loading information

7172748

WARNING

7172566

ATTENTION

Operation of this vehicle without the air filter

element will severely damage the engine.

Clean pre-filter element often, more

frequent cleaning required in dusty

conditions. Do not operate vehicle without

pre-filter.

7172921

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SAFETY

Safety Decals and Locations

WARNING

Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle

with guard removed.

Do not modify engine or clutch. Doing so can

cause part failure, possible imbalance, and

excessive engine RPM, which can result in serious

injury or death.

Operating this ATV if you are under

the age of 16 increases your chance

of severe injury or death.

NEVER operate this ATV if you are

under age 16.

NO STEP

7172563

7172559

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.

Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg)

7172749

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SAFETY

Safety Decals and Locations

WARNING

Pushing reverse

override button

may cause

sudden increases

in power and

traction if too

much throttle is

applied. Loss of

control or forward

flipover may

result, especially

in AWD. See

Owner’s Manual.

MANUFACTURED

ALL WHEEL

DRIVE

SWITCH

BY: POLARIS IND. INC.

DATE:

VIN:

Do not push switch to

engage AWD if the rear

wheels are spinning.

This may cause severe

drive shaft and clutch

damage.

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT

INTENDED FOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST

PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

See your Owner’s

Manual.

7172564

7079780

7171492

Canadian Certification Decal

TRAILER MAX WEIGHT:

1500 LBS. (682 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68KG)

7170509

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SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires

special protective clothing for comfort and to reduce the chance of

injury.

1. Helmet

Your helmet is the most important piece

of protective gear for safe riding. A

helmet can prevent a severe head injury.

Select an approved helmet that meets

or exceeds your state’s safety standards

and bears either the Department of

Transportation (DOT) label, the

American National Standards

Institute label (ANSI z90.1), or the

Snell Memorial Foundation label.

2. Eye Protection

Do not depend on sunglasses for

proper eye protection. A pair of

goggles or a helmet face shield offer

the best protection for your eyes. They

should be kept clean and be of

shatterproof design (bearing the

markings z2.1 or VESC 8).

3. Gloves

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

protection.

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like

moto-cross boots.

5. Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide

the best protection.

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SAFETY

Operator Safety

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.

Know Your Vehicle

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

safety, the safety of others, and the protection of our environment.

Read and understand your owner’s manual, which includes valuable

information about all aspects of your vehicle, including safe operating

procedures.

Safety Training

When you purchased your new ATV, your dealer offered a hands-on

safety training course that covers all aspects of vehicle safety. You

were also provided with printed materials that explain safe operating

procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV from a party other than a Polaris

dealer, you can request this free safety training from any authorized

Polaris dealer.

A Polaris ATV is an off-road vehicle. Familiarize yourself with all

laws and regulations concerning the operation of this vehicle in your

area.

We strongly advise you to strictly follow the recommended

maintenance program outlined in your owner’s manual. This

preventive maintenance program is designed to ensure that all critical

components on your vehicle are thoroughly inspected at specific

intervals.

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SAFETY

Operator Safety

The following signal words and symbols appear throughout this

manual and on your vehicle. Your safety is involved when these words

and symbols are used. Become familiar with their meanings before

reading the manual.

The safety alert symbol, on your vehicle or in this manual, alerts

you to the potential for personal injury.

WARNING

The safety alert warning indicates a potential hazard that may

result in serious injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may

result in minor personal injury or damage to the vehicle.

CAUTION

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

vehicle.

IMPORTANT

IMPORTANT will alert you to important information or

instructions.

NOTE: A note will alert you to key information or instructions.

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SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these

instructions and procedures, which are outlined in further detail

within your owner’s manual.

S Read this manual and all labels carefully, and follow the operating

procedures described.

S Never operate an ATV without proper instruction. Take a training

course. Beginners should receive training from a certified instructor.

Contact an authorized Polaris ATV dealer or call Polaris at

1-800-342-3764 to find out about the training courses nearest you.

S Never allow anyone under 16 years of age to operate this ATV.

S Never permit a guest to operate the ATV unless the guest has read

this manual and all product labels and has completed a certified safe-

ty training course.

S Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

S Never operate an ATV on a public street, road or highway, including

a dirt or gravel road.

S Never operate an ATV without wearing an approved helmet that fits

properly. Always wear eye protection (goggles or face shield),

gloves, boots, a long-sleeved shirt or jacket, and long pants.

S Never consume alcohol or drugs before or while operating an ATV.

S Never operate at excessive speeds. Travel at speeds appropriate for

the terrain, visibility and operating conditions, and your experience.

S Never attempt wheelies, jumps or other stunts.

S Always inspect your ATV before each use to make sure it’s in safe

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner’s manual.

S Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain.

S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speeds.

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SAFETY

Operator Safety

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S Never operate on hills too steep for the ATV or for your abilities.

Practice on smaller hills before attempting larger hills.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascending a hill. Never climb hills with exces-

sively slippery or loose surfaces. Shift your weight forward. Never

open the throttle suddenly or make sudden gear changes. Never go

over the top of a hill at high speed.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill.

Shift your weight backward. Never go down a hill at high speed.

Avoid going down a hill at an angle, which would cause the vehicle

to lean sharply to one side. Travel straight down the hill when pos-

sible.

S Always follow proper procedures for crossing the side of a hill.

Avoid hills with excessively slippery or loose surfaces. Shift your

weight to the uphill side of the ATV. Never attempt to turn the ATV

around on any hill until you’ve mastered (on level ground) the turn-

ing technique outlined in this manual. Avoid crossing the side of a

steep hill when possible.

S Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when

climbing a hill. If you stall or roll backwards, follow the special

procedure for braking described in this manual. Always dismount

on the uphill side, or to either side if the ATV is pointed straight

uphill. Turn the ATV around and remount following the procedure

described in this manual.

S Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees.

Always follow proper procedures when operating over obstacles as

described in this manual.

S Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skid-

ding or sliding out of control.

S Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable, travel slowly, balance your weight carefully, avoid 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.

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SAFETY

Operator Safety

S 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.

S 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.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

S Never exceed the stated load capacity for your ATV. Cargo must be

properly distributed and securely attached. Reduce speed and follow

the instructions in this manual for carrying cargo or towing. Allow a

greater distance for braking.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

sumer Product Safety Commission at 1-800-638-2772, or call

Polaris at 1-800-342-3764.

Equipment Modifications

We are concerned for the safety of our customers and for the general

public. Therefore, we strongly recommend that consumers do not

install on a Polaris ATV any equipment that may increase the speed or

power of the vehicle, or make any other modifications to the vehicle

for these purposes. Any modifications to the original equipment of the

vehicle create a substantial safety hazard and increase the risk of bodily

injury.

The warranty on your Polaris ATV is terminated if any equipment has

been added to the vehicle, or if any modifications have been made to

the vehicle, that increase its speed or power.

NOTE: The addition of certain accessories, including (but not limited

to) mowers, blades, tires, sprayers, or large racks, may

change the handling characteristics of the vehicle. Use only

Polaris-approved accessories, and familiarize yourself with

their function and effect on the vehicle.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the operator does

not know how to operate the ATV properly in different situations

and on different types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should complete the

certified training course offered by Polaris. Operators should

regularly practice the skills learned in the course and the

operating techniques described in the owner’s manual.

For more information about the training course, contact an

authorized ATV dealer or call Polaris at 1-800-342-3764.

WARNING

POTENTIAL HAZARD

Failure to follow the age recommendations for this ATV.

WHAT CAN HAPPEN

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

minimum age recommendation operates an ATV.

Even though a child may be within the recommended age group

for operating some ATVs, he/she may not have the skills,

abilities, or judgment needed to operate an ATV safely and could

be susceptible to accident or injury.

HOW TO AVOID THE HAZARD

No one under the age of 16 should operate a Polaris ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Carrying a passenger

greatly reduces the

operator’s ability to balance

and control the ATV, which

could cause an accident

and injury to the operator

and/or passenger.

HOW TO AVOID THE HAZARD

Never carry a passenger. The purpose of the long seat is to

allow the operator to shift position as needed during operation. It

is not intended for carrying passengers.

WARNING

POTENTIAL HAZARD

Operating an ATV on paved

surfaces, including

sidewalks, paths, parking

lots, and driveways.

WHAT CAN HAPPEN

ATV tires are designed for

off-road use. Operating on paved

surfaces may 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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV on

public streets, roads or

highways.

WHAT CAN HAPPEN

The ATV could collide with

another vehicle.

HOW TO AVOID THE HAZARD

Never operate the ATV on any

public street, road or highway,

including dirt and gravel roads. In many states it’s illegal to

operate ATVs on public streets, roads and highways.

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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seriously affect

operator judgment. Reaction time may be slower and operator

balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an

ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD

Never consume alcohol or drugs before or while operating an

ATV.

WARNING

POTENTIAL HAZARD

Operating the ATV at excessive speeds.

WHAT CAN HAPPEN

Excessive speed increases the operator’s chance of losing

control of the ATV, which can result in an accident causing severe

injury or death.

HOW TO AVOID THE HAZARD

Always operate the ATV at a speed that’s proper for the terrain,

visibility and operating conditions, and your experience.

WARNING

POTENTIAL HAZARD

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.

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SAFETY

Operator Safety

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.

WARNING

POTENTIAL HAZARD

Removing hands from the handlebars or feet from the footrests

during operation.

WHAT CAN HAPPEN

Removing even one hand or foot can reduce ability to control the

vehicle or could cause loss of balance and ejection from the ATV.

If the operator’s foot is not firmly planted on the footrest, it could

come into contact with the rear wheels and lead to accident or

injury.

HOW TO AVOID THE HAZARD

Always keep both hands on the handlebars and both feet on the

footrests of the ATV during operation.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution

when operating the ATV on

unfamiliar terrain.

WHAT CAN HAPPEN

Unfamiliar terrain may

contain hidden rocks, bumps,

or holes that could cause loss

of control or overturn.

HOW TO AVOID THE HAZARD

Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Turning improperly.

WHAT CAN HAPPEN

Improper turns could cause loss of control and lead to a collision

or overturn.

HOW TO AVOID THE HAZARD

Always follow proper procedures for turning as described in the

owner’s manual.

Practice turning at slow speeds before attempting to turn at faster

speeds.

Never turn at excessive speed.

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

Never operate on hills too steep for the ATV or for your abilities.

Never operate the ATV on hills steeper than 25_.

Practice on smaller hills before attempting large hills.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Climbing hills improperly.

WHAT CAN HAPPEN

Improper hill climbing could

cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper

procedures for climbing hills

as described in the owner’s manual.

Always check the terrain carefully before ascending any hill.

Never operate the ATV on hills steeper than 25_.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV

could flip over backwards.

Never go over the top of any hill at high speed. An obstacle, a

sharp drop, or another vehicle or person could be on the other

side of the hill.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Traveling downhill improperly.

WHAT CAN HAPPEN

Improperly descending a hill

could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Always follow proper

procedures for traveling down

hills as described in the

owner’s manual. NOTE: A

special technique is required when

braking while traveling downhill.

See page 57.

Always check the terrain carefully before descending a hill.

Shift your weight backward.

Never travel down a hill at high speed.

Avoid traveling down a hill at an angle, which would cause the

vehicle to lean sharply to one side. Travel straight down the hill

when possible.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly crossing hills and

turning on hills.

WHAT CAN HAPPEN

Improperly crossing or turning as

hills could cause loss of control or

overturn.

HOW TO AVOID THE HAZARD

Never attempt to turn the ATV

around on any hill until you’ve

mastered the turning technique

(on level ground) as described in

the owner’s manual. See page 58.

Use extra caution when turning on any hill.

Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner’s

manual.

Avoid hills with excessively slippery or loose surfaces.

Shift your weight to the uphill side of the ATV.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards

or improperly dismounting

while climbing a hill.

WHAT CAN HAPPEN

The vehicle could overturn.

HOW TO AVOID THE HAZARD

Maintain steady speed when

climbing a hill.

If all forward speed is lost:

Keep your weight uphill.

Apply the brakes.

Lock the parking brake when fully stopped.

If the ATV begins rolling backwards:

Keep weight uphill.

Never apply engine power.

Never apply the rear brake while rolling backwards.

Apply the single-lever brake gradually.

When fully stopped, apply the rear brake as well, and then lock

the parking brake.

Dismount on uphill side, or to either side if ATV is pointed straight

uphill.

Turn the ATV around and remount, following the procedure

described in the owner’s manual. See page 58.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Improperly operating over obstacles.

WHAT CAN HAPPEN

Operating over obstacles could cause loss of control or overturn.

HOW TO AVOID THE HAZARD

Before operating in a new area, check for obstacles.

Avoid operating over large obstacles such as rocks and fallen

trees when possible. If unavoidable, use extreme caution and

always follow proper procedures as outlined in the owner’s

manual.

WARNING

POTENTIAL HAZARD

Skidding or sliding.

WHAT CAN HAPPEN

Skidding or sliding can cause loss of control.

If the tires regain traction unexpectedly, the ATV could overturn.

HOW TO AVOID THE HAZARD

On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV through deep or fast-flowing water.

WHAT CAN HAPPEN

Tires may float, causing loss of traction and loss of control, which

could lead to an accident or overturn.

HOW TO AVOID THE HAZARD

Avoid operating the ATV through deep or fast-flowing water. If it’s

unavoidable to enter water that exceeds the recommended

maximum depth (see page 59), travel slowly, balance your weight

carefully, avoid sudden movements, and maintain a slow and

steady forward motion. Do not make sudden turns or stops, and

do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the

brakes after leaving water. If necessary, apply them several

times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD

Improperly operating in reverse.

WHAT CAN HAPPEN

The ATV could collide with an obstacle or person, resulting in

severe injury.

HOW TO AVOID THE HAZARD

Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly.

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SAFETY

Operator Safety

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.

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.

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SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Overloading the ATV or carrying/towing cargo improperly.

WHAT CAN HAPPEN

Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD

Never exceed the stated load capacity for this ATV.

Cargo should be properly distributed and securely attached.

Reduce speed when carrying cargo or pulling a trailer. Allow a

greater distance for braking.

Always follow the instructions in the owner’s manual for carrying

cargo or pulling a trailer.

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.

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SAFETY

Operator Safety

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.

WARNING

Safe operation of this rider-active vehicle requires good

judgement and physical skills. Persons with cognitive or physical

disabilities who operate this vehicle have an increased risk of

overturn and loss of control, which could result in severe injury or

death.

CAUTION

Exposure to the hot components could result in a fire. Always

keep combustible materials away from the exhaust system.

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FEATURES AND CONTROLS

Engine Electrical Switches

WARNING

Activating the override switch while the throttle is open can cause

loss of control, resulting in severe injury or death. Do not activate

the override switch while the throttle is open.

Mode/Reverse Override Switch (1) - This vehicle is equipped with a

reverse speed limiter system. To gain additional power while backing,

depress the override switch.

NOTE: The override switch also allows activation of All Wheel Drive

in reverse, if the AWD switch is on. This switch is also used

to toggle through the different modes of the rider information

center. See page 40.

Engine Stop Switch (2) - The engine will

OFF

RUN

not start or run when the switch is in the

OFF position. Its purpose is to provide the

operator with a quick means of engine

shutdown in case of an emergency.

NOTE: The cooling fan motor does not shut off when the stop switch

is used to stop the engine. Turn off the main ignition switch

to turn off the cooling fan motor.

Main Switch (3) - To start the engine, slide the stop switch to the

center RUN position and turn the main key switch clockwise past the

ON position. Release the key when the engine starts.

NOTE: Both the main switch and the emergency engine stop switch

will shut off all electrical power to the vehicle, including lights.

To stop the engine, slide the stop switch either right or left to

the OFF position.

Worklight Switch (4)

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FEATURES AND CONTROLS

WARNING

Operating an ATV with sticking or improperly operating throttle

controls could cause an accident and lead to severe injury or

death.

Never start or operate an ATV with a sticking or improperly

operating throttle. Always contact your dealer for service if throttle

problems arise.

Failure to check or maintain proper operation of the throttle

system can result in an accident if the throttle lever sticks during

operation. Always check the lever for free movement and return

before starting the engine. Also check occasionally during

operation.

Throttle Lever

Engine speed and vehicle movement

are controlled by pressing the

throttle lever (1). The throttle lever

is spring loaded. Engine speed

returns to idle when the lever is

released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC),

which is designed to reduce the risk of a frozen or stuck throttle. If the

throttle cable should stick in an open position when the operator

releases the throttle lever, the engine will stop, and power to the rear

wheels will cease.

WARNING

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.

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FEATURES AND CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the

lights on and off and to switch the lights from HI to LO.

NOTE: The lights won’t work unless the key is in the ON position

and the auxiliary shut-off switch is in the RUN position.

WARNING

Operating the ATV on streets or roads, especially in darkness,

could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It’s

designed for and must be used for off-road use only. Use caution

and drive at reduced speeds in conditions of reduced visibility

such as fog, rain and darkness.

Brake Lever

The front and rear brakes are applied

by squeezing the brake lever (1)

toward the handlebar. The front and

rear brakes are hydraulically

activated disc type brakes that are

activated by only one lever.

Always test brake lever travel and

master cylinder fluid level before riding.

When squeezed, the lever should feel firm. Any sponginess would

indicate a possible fluid leak or low master cylinder fluid level, which

must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of

braking, which could cause an accident. Never operate the ATV

with a spongy-feeling brake lever.

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FEATURES AND CONTROLS

Master Cylinder

The brake fluid in the master

cylinder (1), which is located on the

left handlebar, should be checked

before each ride. The fluid level

can be seen through an indicator

window (2) on the top of the master

cylinder. This eye will appear dark

when the fluid level is full. When

fluid needs to be added, the eye will be clear.

NOTE: When checking the fluid level, the ATV must be on level

ground with the handlebars straight. If the fluid level is low

add DOT 3 brake fluid only. See page 107 for the part

numbers of Polaris products.

WARNING

After opening a bottle of brake fluid, always discard any unused

portion. Never store or use a partial bottle. Brake fluid is

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

drop, which can lead to early brake fade and the possibility of

accident or severe injury.

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FEATURES AND CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could

result in an accident and serious injury or death. Always check to

be sure the parking brake is disengaged before operating.

Setting the Parking Brake

1. Place the transmission in park.

2. Squeeze and release the brake

lever (1) two or three times, then

squeeze and hold.

3. Push the park brake lock (2)

forward to engage the brake.

Release the brake lever.

4. To release the parking brake

lock, squeeze and release the brake

lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a long period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

it parked on a hill. Another option is to park the ATV in a sidehill

position.

S Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

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FEATURES AND CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the auxiliary brake when backing down a

hill may cause rear tipover, which could result in serious injury or

death.

Use caution when applying the auxiliary brake. Do not

aggressively apply the auxiliary brake when going forward. The

rear wheels may skid and slide sideways, causing loss of control

and serious injury or death.

Your Polaris ATV has an

auxiliary brake (1) for added

safety. It’s located on the

inside of the right floor board

and is operated by the right

foot. The auxiliary brake

serves as a backup to the main

brake system if the main

system becomes inoperative.

If the rear wheels slide while

using the auxiliary brake,

reduce brake pedal pressure to brake the rear wheels without skidding.

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system.

The reservoir is located under the seat or near the auxiliary brake.

Maintain the fluid level between the maximum and minimum marks.

Fuel Tank

The fuel tank filler cap (1) is located

directly below the handlebar. Use either

leaded or unleaded gasoline with a

minimum pump octane number of

87=(R+ M/2) octane.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 200

hours of operation and any time the fuel becomes contaminated with

dirt or debris. Do not attempt to clean the fuel filter.

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the

vehicle.

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

To shift into HIGH or PARK, you must first apply the auxiliary brake

to activate the high/park lock-out mechanism. When shifting out of

HIGH or PARK, it’s not necessary to apply the brake.

Whenever the ATV is left unattended, always place the transmission in

park and lock the parking brake.

CAUTION

Shifting gears with the engine speed above idle or while the

vehicle is moving could cause transmission damage.

To change gears, stop the vehicle, and with the engine idling,

move the lever to the desired gear. Apply the auxiliary brake if

shifting into HIGH or PARK.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and

when operating at less than seven miles per hour for extended periods of

time.

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FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Polaris 4-wheel drive ATVs are

equipped with a unique,

Polaris-exclusive, On-Demand All

Wheel Drive system, which is

activated by the AWD switch (1) on

the right handlebar. When the

switch is off, the ATV is in

two-wheel drive at all times. When the switch is on, the ATV is in

AWD and the AWD indicator light in the instrument cluster will be on.

When in AWD, the front gearcase will automatically engage any time

the rear wheels lose traction. When the rear wheels regain traction, the

front gearcase will automatically disengage.

NOTE: The override switch allows activation of AWD in reverse if the

AWD switch is on. See page 32.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging the Front Gearcase

The AWD switch may be turned on or off while the vehicle is moving.

Initially, the vehicle’s electronic system will not enable the AWD until

the engine RPM is below 3100. Once enabled, the AWD remains

enabled until the AWD switch is turned off. If the switch is turned off

while the front gearcase is moving, it will not disengage until the rear

wheels regain traction.

Engage the AWD switch before getting into conditions where front

wheel drive may be needed. If the rear wheels are spinning, release the

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause

severe drive shaft and gearcase damage. Always switch to AWD

while the rear wheels have traction or are at rest.

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FEATURES AND CONTROLS

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle

speed from the right front wheel. The instrument cluster measures

distance in miles as well as hours of operation. It also includes a

reverse speed limiter function that limits the ATV’s speed to

approximately 7-9 mph. Refer to page 32 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the

needle flashes when a warning condition exists.

3. Speedometer

CAUTION

High water pressure may damage ATV components. Wash the

ATV by hand or with a garden hose using mild soap.

Certain products, including insect repellants and chemicals, will

damage the speedometer lens and other plastic surfaces. Do not

use alcohol to clean the instrument cluster. Do not allow insect

sprays to come into contact with the lens. Immediately clean off

any gasoline that splashes on the instrument cluster.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All

segments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery

over-voltage may have occurred and the instrument cluster

may have shut off to protect the electronic speedometer. If

this occurs, take the ATV to your Polaris dealer for proper

diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the

gear the transmission is in:

H = High Range

L = Low Range

N = Neutral

R = Reverse

P = Park

2. AWD Indicator - This

indicator illuminates

when the electrical

portion of the AWD

system is enabled.

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. A low battery warning may also occur under normal

operation if the machine is at idle and high electrical load (lights,

cooling fan, accessories) is applied. Driving at a higher RPM or

connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge show the level of

fuel in the fuel tank. When the last segment clears, a low fuel

warning is activated. All segments will flash, FUEL will display

in the LCD, and the speedometer needle will blink. Refuel

immediately.

8. Check Engine Warning Indicator - This indicator serves two

purposes. The word HOT displays if the engine overheats. It also

appears if an EFI-related fault occurs. Do not operate the ATV if

this warning appears. Serious engine damage could result.

9. Mode Indicator

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes:

Mode 1 - Odometer

Mode 2 - Tripmeter

Mode 3 - Total Service Hours

Mode 4 - Tachometer

The reverse override button on the left handlebar is also the mode

button.

NOTE: If using the mode button to program the rider information

center, or to toggle through the options, the machine cannot

be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

The trip meter records the miles traveled by the ATV on each trip if it’s

reset before each trip. To reset the trip meter, select the trip meter

mode. Press and hold the mode button (override button) until the total

changes to 0.

NOTE: In the Rider Information Center, the trip meter display

contains a decimal point, but the odometer displays without a

decimal point.

Mode 3 - Hour Meter

This mode logs the total hours the engine has been in operation.

Mode 4 - Tachometer

The engine RPM is displayed digitally.

NOTE: Small fluctuations in the RPM from day to day may be

normal because of changes in humidity, temperature and

elevation.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return

your ATV to your dealer for all major repairs.

As long as the gauge is in the diagnostic mode, the wrench icon will

remain lit.

To leave the diagnostic mode, turn the key switch off and on.

NOTE: Any movement of the tires will also take the machine out of

the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Set the park brake and shift the transmission into neutral.

3. Hold the mode/reverse override button and turn the key switch on.

4. Release the switch as soon as the display is activated.

The initial screen display refers to the software version installed in

your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic

screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the

AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic

This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval

The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine

maintenance. When your vehicle leaves the factory, this feature is set at

50 hours. You must enable the programmable service interval before it

can be used.

Once the service interval mode is set with the hours when service is

due, the hours of actual engine operation are subtracted from the set

hours until 0 is reached. When the counter reaches 0, the wrench icon

will flash quickly for 5 seconds each time the vehicle is started as a

reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the

wrench icon flashes. When it begins to flash, release the button. The

setting will increase by one hour each time the button is pressed.

Pressing and holding the button will allow the numbers to escalate

much faster. When the desired time increment is displayed, release the

button and wait for the wrench to stop flashing. When the wrench

stops blinking, your service hours are set.

NOTE: If you scroll past the intended number, hold the button down

until the count turns over to 0. You can then reset the

number.

If the service interval is enabled on your ATV and you wish to turn it

off, toggle to the service interval mode. Press and hold the mode

button for approximately 7 seconds until the word OFF appears in the

Rider Information Center.

Screen 6: Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as

KM or MP. To change, hold in the mode button until the letters flash,

then press and release the button once. When the display stops

flashing, the mode has been set.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Special EFI Diagnostic Mode

The EFI diagnostic mode is for informational purposes only. Please

see your Polaris dealer for all major repairs. To download blink codes

(failure codes) from the EFI module:

1. Place the transmission in PARK, turn the engine off and turn the

key switch to the ON position.

2. Turn the key switch off and on three times in less than five

seconds, then leave the switch on. Any blink code numbers stored

in the EFI module will display, one at a time, in the alphanumeric

display. The number “61” and the word “END” will display after

all codes have been transmitted.

Blink

Code

Failure Description

Blink

Code

Failure Description

No RPM Signal

Engine Temp Lamp: Open Load

Loss of Synchronization

Engine Temp Lamp: Short Circuit

to Ground

Barometric Pressure Sensor:

Circuit Low Input

Engine Temp Lamp: Short Circuit

to Battery

Barometric Pressure Sensor:

Circuit High Input

Diag Lamp: Open Load

TPS: Open or Short Circuit to

Ground

Diag Lamp: Short Circuit to

Ground

TPS: Short Circuit to Battery

Diag Lamp: Short Circuit to

Battery

RAM Error: Defective ECU

Pump Relay: Open Load

Engine Temp Sensor Circuit:

Short to Ground

Pump Relay: Short Circuit to

Ground

Engine Temp Sensor Circuit:

Open or Short to Battery

Pump Relay: Short Circuit to

Battery

Injector 1: Open Load

Intake Air Temp Sensor: Open or

Short Circuit to +Sensor Voltage

Injector 1: Short Circuit to Ground

Intake Air Temp Sensor: Short

Circuit to Ground

Injector 1: Short Circuit to Battery

Injector 2: Open Load

END

Injector 2: Short Circuit to Ground

Injector 2: Short Circuit to Battery

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OPERATION

Fuel Safety

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.

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.

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OPERATION

Break-In Period

The break-in period for your new Polaris ATV is defined as the first ten

hours of operation, or the time it takes to use the first two full tanks of

gasoline. No single action on your part is as important as following

the procedures for a proper break-in. Careful treatment of a new

engine will result in more efficient performance and longer life for the

engine. Perform the following procedures carefully.

CAUTION

Excessive heat build-up during the first three hours of operation

will damage close-fitted engine parts. Do not operate at full

throttle or high speeds for extended periods during the first three

hours of use.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 synthetic Oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

1. Fill the fuel tank with gasoline. See page 37.

2. Check the engine oil level on the dipstick. See page 71. Add oil

if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 48.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20

hours or one month.

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OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury

or death could result. Always inspect the vehicle before each use

to ensure it’s in proper operating condition.

Pre-Ride Checklist

Item

Remarks

See

Page

Brake system / lever travel

Brake fluid

Ensure proper operation

Ensure proper level

34, 78

Auxiliary brake

Front suspension

Rear suspension

Steering

Ensure proper operation

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

82,109

Wheels / fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Ensure proper level

Coolant level (if applicable)

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

33,102

Indicator lights / switches

Engine stop switch

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure operation

Ensure proper operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light / tail lamp

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Wear helmet, goggles, protective

clothing

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OPERATION

Starting the Engine

WARNING

Engine exhaust contains poisonous carbon monoxide and can

cause loss of consciousness resulting in severe injury or death.

Never run an engine in an enclosed area.

1. Position the vehicle on a level surface with the transmission in

PARK.

2. Lock the park brake, sit on the vehicle and turn the engine stop

switch to RUN.

NOTE: Do not press the throttle while starting the engine.

3. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the

key when the vehicle starts. If the engine does not start, release the

key, allowing it to return to the ON position, and wait five seconds.

Activate the starter for another five seconds if necessary. Repeat

this procedure until the engine starts.

CAUTION

Operating the vehicle immediately after starting could cause

engine damage. Allow the engine to warm up for several minutes

before operating the vehicle.

Cold Weather Operation

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

oil level could indicate the accumulation of contaminates such as water

or excess fuel in the bottom of the crankcase. Water in the bottom of

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

accumulation increases as outside temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker

warm-ups and easier starting in colder weather.

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OPERATION

Hauling Cargo

1/3

2/3

Your ATV has been designed to carry or tow a certain amount of load.

Always read and understand the load distribution warning labels on the

vehicle, and never exceed the weight capacities outlined in the

specifications section of the owner’s manual and on the safety decals.

Cargo weight should be evenly distributed (1/3 on the front rack and

2/3 on the rear rack) and mounted as low as possible. When operating

over rough or hilly terrain, reduce speed and cargo weight to maintain

stable driving conditions. Do not obstruct the headlight beam with

cargo.

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend

belt life.

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OPERATION

Hauling Cargo

WARNING

Hauling cargo improperly can alter vehicle handling and may

cause loss of control or brake instability and result in serious

injury or death. Always follow these precautions when hauling

cargo:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR

BRAKING WHEN HAULING CARGO.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front

rack and 2/3 on the rear rack. When operating over rough or hilly

terrain, reduce speed and cargo to maintain stable driving

conditions. Carrying loads on one rack only increases the

possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE.

Carrying loads high on the racks raises the center of gravity of

the vehicle and creates a less stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads

can create unstable operating conditions, which could result in

loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED

LOADS. When handling off-centered loads that cannot be

centered, securely fasten the load and operate with extra caution.

Always attach the tow load to the hitch point designated for your

vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL

PROBLEMS. Use extreme caution when applying brakes with a

loaded vehicle. Avoid terrain or situations that may require

backing downhill.

USE EXTREME CAUTION when operating with loads that extend

over the rack sides. Stability and maneuverability may be

adversely affected, causing the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when

carrying loads on the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED

SPEEDS. Vehicle should never exceed 10 mph (16 kph) while

towing a load on a level grass surface. Vehicle speed should

never exceed 5 mph (8 kph) when towing loads in rough terrain,

while cornering, or while ascending or descending a hill.

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OPERATION

Driving Safely

Driving Procedures

1. Sit upright with both feet on the footrests and both hands on the

handlebars.

2. Start the engine and allow it to warm up, then shift the

transmission into gear.

3. Check your surroundings and determine your path of travel.

4. Release the parking brake.

5. Slowly depress the throttle with your right thumb and begin

driving. Vehicle speed is controlled by the amount of throttle

opening.

6. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

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OPERATION

Driving Safely

Making Turns

Your ATV is equipped with a

solid rear axle, which drives

both rear wheels equally at all

times. This means that the

wheel on the outside of the

turn must travel a greater

distance than the inside wheel

when turning and the inside

tire must slip traction slightly.

To turn, steer in the direction

of the turn, leaning your upper

body to the inside of the turn

while supporting your weight

on the outer footrest. This

technique alters the balance of

traction between the rear

wheels, allowing the turn to be

made smoothly. The same

leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to

turn at faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in

vehicle overturn and lead to serious injury. Avoid turning at sharp

angles. Never turn at high speeds.

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OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery

surfaces such as wet trails or

loose gravel, or during

freezing weather, follow these

precautions:

1. Slow down when

entering slippery areas.

2. Engage AWD before

wheels begin to lose

traction.

3. Maintain a high level

of alertness, reading the

trail and avoiding quick,

sharp turns, which can cause

skids.

4. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if the AWD is engaged

while the wheels are spinning. Always allow the rear wheels to

stop spinning before engaging AWD, or engage AWD before

wheels begin to lose traction.

WARNING

Failure to exercise care when operating on slippery surfaces can

result in loss of tire traction and cause loss of control, accident,

and serious injury or death.

Never apply the brakes during a skid. Do not operate on

excessively slippery surfaces. Always reduce speed and use

additional caution.

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OPERATION

Driving Safely

Traveling Uphill

25_ Maximum

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (25_ maximum).

3. Keep both feet on the footrests.

4. Transfer your weight forward.

5. Proceed at a steady rate of speed and throttle opening.

6. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

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.

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OPERATION

Driving Safely

Sidehilling

WARNING

Improperly crossing hills or turning on hills can result in loss of

control or vehicle overturn, resulting in severe injury or death.

Avoid crossing the side of a hill when possible. Follow proper

procedures as outlined in the owner’s manual.

Sidehilling can be the most dangerous type of driving encountered and

should be avoided if at all possible. If you do enter into a situation

where sidehilling is necessary, follow these precautions:

1. Slow down.

2. Lean into the hill, transferring your upper body weight toward the

hill while keeping your feet on the footrests.

3. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel

downhill, if possible, or dismount on the uphill side

immediately!

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OPERATION

Driving Safely

Traveling Downhill

WARNING

Excessive speed when traveling downhill can cause loss of

control and serious injury or death.

When traveling downhill, follow these precautions:

1. Transfer your weight to the rear.

2. Drive straight down the hill.

3. Slow down. Squeeze the brake lever gradually.

WARNING: Applying the brakes too firmly may cause the rear

wheels to lock, which could result in loss of control.

Before operating your ATV, learn how the auxiliary brake works in

case you lose your normal service brakes.

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OPERATION

Driving Safely

Turning Around on a Hill

WARNING

Improper hill climbing procedures could cause loss of control or

overturn and result in serious injury or death.

Avoid climbing steep hills (25_ maximum).

Use extreme caution when operating on hills, and follow proper

operating procedures outlined in the owner’s manual.

If the vehicle stalls while climbing a hill, never back it down the hill!

One maneuver that can be used when you must turn around while

climbing a hill is the K-turn:

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. Dismount on the uphill side of the vehicle, or on the left if the

vehicle is pointing straight uphill.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the service brake, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it’s

pointing across the hill or slightly downward.

6. Lock the parking brake and remount the vehicle from the uphill

side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed

with the service brake, until the vehicle is on more level ground.

8’

Uphill

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OPERATION

Driving Safely

Driving Through Water

Your ATV can operate through water

with a maximum recommended

depth equal to the bottom of

the footrests (1). Follow

these procedures when

operating through water:

1. Determine water depths

and current before

crossing.

2. Choose a crossing where

both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles if possible.

4. After crossing, dry the brakes by applying light pressure to the

lever until braking action is normal.

After running the vehicle in water, it’s critical to have it serviced as

outlined in the maintenance chart. See page 64. The following areas

need special attention: engine oil, transmission oil, front and rear

gearcases, and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined

in the maintenance chart.

If your vehicle becomes immersed or is operated in water that

exceeds the footrest level, take it to your dealer for service before

starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing

water. If you cannot avoid water that exceeds the

recommended maximum depth, go slowly, balance your

weight carefully, avoid sudden movements, and maintain a

slow and steady forward motion. Do not make sudden turns

or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it’s impossible to take it to a

dealer before starting it, follow the steps described on page 90. Have

the vehicle serviced by your dealer at the first opportunity.

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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.

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.

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OPERATION

Driving Safely

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always avoid

backing downhill.

2. Back slowly.

3. When in reverse,

apply the brakes

lightly for

stopping.

4. Avoid turning at

sharp angles in

reverse.

5. Never open the

throttle suddenly

while backing.

WARNING

Failure to use caution when operating in reverse can result in

serious injury or death. Before shifting into reverse, always check

for obstacles or people behind the vehicle. When it’s safe to

proceed, back slowly.

Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter.

The override button should be used with caution as rearward

vehicle speed is greatly increased. Do not operate at wide

open throttle. Open the throttle just enough to maintain a

desired speed.

CAUTION

Excessive throttle operation while in the speed limit mode may

cause fuel to build in the exhaust, resulting in engine popping

and/or engine damage.

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OPERATION

Driving Safely

Parking on an Incline

Avoid parking on an incline if possible. If it’s unavoidable, follow

these precautions:

1. Turn the engine off.

2. Place the transmission in park.

3. Set the parking brake.

4. Always block the rear wheels on the downhill side as shown.

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EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so

may affect compliance with state and local noise level requirements.

Spark Arrestor

Your Polaris vehicle has a spark arrestor that was tested and qualified

to be in accordance with the USDA Forest Service Standard 5100-1C.

Federal law requires that this spark arrestor be installed and functional

when the vehicle is operated on public lands.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel

injection (EFI) system controls fuel delivery. The engine and EFI

components are set at the factory for optimal performance and are not

adjustable.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by

gases are forced back to the combustion chamber by the intake system.

The system does not allow the blow-by gases to enter the atmosphere.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES--002 and

European directives 97/24/EC and 89/336/EEC.

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MAINTENANCE AND LUBRICATION

Accessories

Auxiliary power outlets provide 12V power for operating accessories

such as hand held spot lights. See your Polaris dealer.

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

NOTE: Service and adjustments are critical. If you’re not familiar

with safe service and adjustment procedures, have a

qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour. Vehicles subjected to severe use must be inspected and

serviced more frequently.

Severe Use Definition

S Frequent immersion in mud, water or sand

S Racing or race-style high RPM use

S Prolonged low speed, heavy load operation

S Extended idle

S Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold

weather can indicate contaminants collecting in the oil sump or

crankcase. Change oil immediately if the oil level begins to rise.

Monitor the oil level, and if it continues to rise, discontinue use and

determine the cause or see your dealer.

Maintenance Chart Key

Perform these procedures more frequently for vehicles subjected to

severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a J could

result in component failure and lead to serious injury or death.

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Make adjustments as need-

ed. See Pre-Ride Checklist

on page 48.

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

Engine oil level

Air filter, pre-filter

Daily

Inspect; clean often

Air box sediment

tube

Drain deposits when visible

Coolant

(if applicable)

Daily

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp/worklight

Daily

Check operation; apply

dielectric grease if replacing

Air filter,

main element

Weekly

Inspect; replace as needed

Recoil housing

(if applicable)

Drain water as needed,

check often if operating in

wet conditions

Brake pad wear

10 H

Monthly

100 (160)

Inspect periodically

Battery

20 H

25 H

Monthly

200 (320)

250 (400)

Check terminals; clean; test

Inspect level; change yearly

Front gearcase oil

(if equipped)

Rear gearcase oil

(if equipped)

25 H

Monthly

250 (400)

Inspect level; change yearly

Perform these procedures more often for vehicles subjected to severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Transmission oil

25 H

Monthly

250 (400)

Inspect level; change yearly

Inspect; clean if needed

Engine breather

filter (if equipped)

General

lubrication

50 H

3 M

6 M

500 (800)

Lubricate all fittings, pivots,

cables, etc.

Carburetor float

bowl

Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

Inspect; adjust; lubricate;

replace if necessary

Choke cable

(if applicable)

Inspect; adjust; lubricate;

replace if necessary

Carburetor air

intake ducts/

flange

Inspect ducts for proper

sealing/air leaks

(if applicable)

Drive belt

50 H

6 M

500 (800)

Inspect; adjust; replace as

needed

Cooling system

(if applicable)

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

Engine oil change 100 H

6 M

1000 (1600) Perform a break-in oil

change at one month

Oil filter change

Valve clearance

Fuel system

100 H

1000 (1600) Replace with oil change

12 M

1000 (1600) Inspect; adjust

1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

Radiator

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

(if applicable)

Cooling hoses

(if applicable)

1000 (1600) Inspect for leaks

Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Perform these procedures more often for vehicles subjected to severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Chart

Item

Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar

Miles

(Km)

Spark plug

Ignition Timing

Wiring

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Clutches (drive

and driven)

100 H

12 M

1000 (1600) Inspect; clean; replace worn

parts

Front wheel

bearings

1000 (1600) Inspect; replace as needed

Brake fluid

Fuel filter

200 H

24 M

2000 (3200) Change every two years

2000 (3200) Check for leaks around

lines. Replace every 2

years, more often under

extreme conditions.

Spark arrestor

Idle speed

300 H

36 M

3000 (4800) Clean out

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

Perform these procedures more often for vehicles subjected to severe use.

Emission Control System Service (California)

Have an authorized Polaris dealer perform these services.

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Record

Use the following chart to record periodic maintenance.

Maintenance

Interval

Performed

Servicing Servicing

Remarks

Date

Dealer

or Person

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MAINTENANCE AND LUBRICATION

Lubrication Guide

Check and lubricate all components at the intervals outlined in the

Periodic Maintenance Chart beginning on page 64. Items not listed in

the chart should be lubricated at the General Lubrication interval.

Lubrication Guide Key

More often under severe use, such as wet or dusty conditions

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item

Lube

Method

Engine Oil

Polaris Premium 4

Synthetic 0W40

Add to proper level on dipstick.

Brake Fluid

DOT 3 Only

Maintain level between fill lines. See

page 35.

Transmission Oil

Front Gearcase Oil

Rear Gearcase Oil

Polaris AGL Synthetic

Gearcase Lube

See page 73.

See page 74.

See page 75.

Premium Demand

Drive Hub Fluid

ATV Angle Drive Fluid

(or GL5 80-90 weight

gear lube)

Front Prop Shaft Yoke

(Fig. 1)

FGrease

Grease fittings (3 pumps maximum)

Ball Joint (Fig. 2)

Locate fitting on back side of struts

and grease with grease gun.

"LGrease

(Fig. 1)

(Fig. 2)

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MAINTENANCE AND LUBRICATION

Premium 4 Synthetic Lubricant

Polaris Premium 4 All Season synthetic engine oil has been specially

formulated for use in Polaris 4-cycle engines. It’s a fully synthetic,

high performance, multi-viscosity oil designed to provide the ultimate

in lubrication performance and protection. See page 107 for the part

numbers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest

possible temperature range. It resists viscosity and frictional

breakdown in ambient temperatures from -40° F. to 120° F. (-40 to

+49° C.) Its exceptional frictional properties result in more efficient

operation, more power output and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in

this engine, use of any API certified SH oil is allowable as long as it’s

0W-40. Oil may need to be changed more frequently if Polaris

Premium 4 is not used. Follow the manufacturer’s recommendations

for ambient temperature operation.

CAUTION

Mixing brands or using a non-recommended oil may cause

serious engine damage. We recommend the use of Polaris

Premium 4 synthetic oil or another 0W-40 API certified SH oil.

Never substitute or mix oil brands.

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MAINTENANCE AND LUBRICATION

Oil Level

The oil dipstick and fill tube (1) is located on the engine and is

accessible on the left side of the ATV.

1. Position the ATV on a level surface.

2. Start the engine and let it idle for

20-30 seconds, then stop the

engine.

3. Lift the lever lock (2) to remove

the dipstick. Wipe it dry with a

clean cloth.

4. Reinstall the dipstick completely,

but do not lock it. The dipstick

must be inserted completely in to

keep the angle and depth of the

ADD 8 OZ

SAFE

stick consistent.

5. Remove the dipstick

and check the oil level.

Maintain the oil level

in the safe range (3).

Do not overfill.

NOTE: Due to the dipstick entry

angle into the

crankcase, the oil level

will read higher on the

bottom side of the

dipstick. Always read

the level on the upper

surface (4) of the dipstick.

6. After reinstalling the dipstick, be

sure to seat the lever lock.

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MAINTENANCE AND LUBRICATION

Oil and Filter Change

CAUTION

Hot oil can cause serious burns to skin. Do not allow hot oil to

come into contact with skin.

Always change the oil and filter at the intervals outlined in the Periodic

Maintenance Chart beginning on page 64. Always change the oil filter

whenever changing oil.

1. Position the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the

engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath engine crankcase and remove the drain

plug.

5. Allow the oil to drain completely.

6. Replace the sealing washer on the drain plug.

NOTE: The sealing surfaces on drain plug and crankcase should be

clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug and torque to 20 ft. lbs. (27 Nm).

8. Place shop towels beneath the oil filter. Using an oil filter wrench,

turn the filter counterclockwise to remove.

9. Using a clean dry cloth, clean the filter sealing surface on the

crankcase.

10. Lubricate the o-ring on the new filter with a film of fresh engine

oil. Check to make sure the o-ring is in good condition.

11. Install the new filter and turn by hand until the filter gasket

contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of

recommended oil.

13. Place the gear selector in park and set the parking brake.

14. Start the engine and let it idle for one to two minutes. Stop the

engine and inspect for leaks.

15. Re-check the oil level on the dipstick and add oil as necessary to

bring the level to the upper mark on the dipstick.

16. Dispose of used filter and oil properly.

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MAINTENANCE AND LUBRICATION

Transmission Oil

Always check and change the

transmission oil at the intervals outlined

in the Periodic Maintenance Chart

beginning on page 64. Maintain the

transmission oil level at the bottom of

the fill plug hole (1). We recommend

the use of Polaris Premium AGL

Synthetic Gearcase Lubricant. See

page 107 for the part numbers of Polaris

products.

The transmission oil fill plug (2) is located on the right side of the

ATV behind the footwell. The transmission drain plug (3), is located

on the bottom left-hand side of the gearcase.

Oil Check

1. Remove the footwell (see page 81).

2. Remove the fill plug and check the oil level.

3. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

4. Reinstall the footwell.

Oil Change

1. Remove the footwell (see page 81).

2. Remove the drain plug and drain the oil into a drain pan. Dispose

of properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Remove the fill plug and add 15 oz. (450 ml) of the recommended

transmission oil.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

6. Check for leaks.

7. Reinstall the footwell.

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MAINTENANCE AND LUBRICATION

Front Gearcase Oil

Always check and change the front gearcase oil at the intervals

outlined in the Periodic Maintenance Chart beginning on page 66.

Maintain the oil level even with the bottom of the fill hole threads (1).

We recommend the use of Polaris Premium Demand Drive Hub Fluid.

Use of other oils may result in improper operation of components. See

page 107 for the part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug (2) and view

the oil level.

3. Add the recommended gearcase oil

as needed to bring the level to the

bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to

8-10 ft. lbs. (11-14 Nm).

Oil Change

1. Position the vehicle on a level surface

and remove the fill plug.

2. Place a drain pan beneath the

gearcase, remove the gearcase drain

plug (3) located on the bottom

right-hand side, and drain the oil.

3. Clean and reinstall the drain plug.

Torque to 11 ft. lbs. (15 Nm).

4. Add 5 ounces (150 ml) of Polaris

Premium Demand Drive Hub Fluid.

5. Reinstall the fill plug. Torque to 8-10 ft.

lbs. (11-14 Nm).

6. Check for leaks.

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MAINTENANCE AND LUBRICATION

Rear Gearcase Oil

The rear gearcase fill plug (1) is

located on the rear of the

gearcase. Always check and

change the rear gearcase oil at

the intervals outlined in the

Periodic Maintenance Chart

beginning on page 64.

Maintain the rear gearcase

oil level (2) even with the bottom

of the fill hole. We recommend

the use of Polaris ATV Angle

Drive Fluid (or GL5 80-90

weight gear lube). See page 107

for the part numbers of Polaris products.

Oil Check

1. Position the ATV on a level surface.

2. Remove the fill plug and view the oil level through the fill plug

hole.

3. Add the recommended gearcase oil as needed.

4. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

Oil Change

1. Place a drain pan beneath the drain and remove the drain plug (3).

Catch and discard used oil properly.

2. Clean and reinstall the drain plug with a new sealing washer.

Torque to 14 ft. lbs. (19 Nm).

3. Remove the fill plug and add 10 ounces (300 ml) of the

recommended gearcase oil.

4. Inspect the oil level, which should be maintained level with the

bottom of the fill plug hole.

5. Reinstall the fill plug. Torque to 14 ft. lbs. (19 Nm).

6. Check for leaks.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Radiator Coolant Level

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

recommend that the system be completely drained every two years and

a fresh mixture of antifreeze and water added. Polaris recommends the

use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of

high quality aluminum compatible anti-freeze/coolant and distilled

water. Polaris Premium 60/40 is already premixed and ready to use.

Do not dilute with water. See page 107 for the part numbers of Polaris

products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

Any time the cooling system has been drained for maintenance or

repair, replace the coolant. If the recovery bottle has run dry, the level

in the radiator should be inspected. Add coolant as needed.

WARNING

Escaping steam can cause severe burns. Never remove the

pressure cap while the engine is warm or hot. Always allow the

engine to cool before removing the pressure cap.

1. To access the radiator pressure

cap, open the front box lid and

pull open the access door.

2. Remove the pressure cap (1).

3. Using a funnel, slowly add

coolant through the radiator

filler neck.

4. Reinstall the pressure cap,

secure the access door and close

the box.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for

the correct replacement part.

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MAINTENANCE AND LUBRICATION

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the

left side of the machine. To access the

recovery bottle, remove the left side panel

as outlined on page 81.

Maintain the coolant level between the

minimum and maximum marks on the

bottle (when the fluid is cool). Add

coolant as needed.

Cooling System Operation

The engine coolant level is controlled, or maintained, by the recovery

system. The recovery system components are the recovery bottle, the

radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated)

excess coolant is forced out of the engine, past the pressure cap, and

into the recovery bottle. As engine coolant temperature decreases the

contracting (cooled) coolant is drawn back up from the bottle, past the

pressure cap, and into the radiator.

NOTE: Some coolant level drop on new vehicles is normal as the

system is purging itself of trapped air. Observe coolant

levels and maintain as recommended by adding coolant to

the recovery bottle.

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MAINTENANCE AND LUBRICATION

Brakes

The front and rear brakes are hydraulic disc brakes, activated by

moving the single brake lever toward the handlebar. These brakes are

self-adjusting.

The following checks are recommended to keep the brake system in

good operating condition. Check more often if brakes are used heavily

under normal operation.

WARNING

Never store or use a partial bottle of brake fluid. Brake fluid is

hygroscopic, meaning it rapidly absorbs moisture from the air.

The moisture causes the boiling temperature of the brake fluid to

drop, which can lead to early brake fade and the possibility of

accident or severe injury. After opening a bottle of brake fluid,

always discard any unused portion.

1. Always keep brake fluid at an adequate level (see page 35).

WARNING

An over-full master cylinder may cause brake drag or brake

lock-up, which could result in serious injury or death. Maintain

brake fluid at the recommended level. Do not overfill.

NOTE: Under normal operation, the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the

diaphragm is not extended, a leak is likely and the diaphragm

should be replaced. Always fill the reservoir as needed

whenever the cover is loosened or removed to ensure proper

diaphragm operation. Use Polaris DOT 3 brake fluid. Do not

overfill.

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MAINTENANCE AND LUBRICATION

Brakes

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear,

damage and looseness.

5. Check the security and surface

condition of the disc.

NOTE: Replace brake pads when they

are worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the

main brake system. Should the main system fail, the rear brake can be

activated by depressing the foot pedal on the inside of the right

footrest. The hydraulic auxiliary brake system requires no adjustment.

NOTE: Since this is a rear brake only, it will not be as effective as

the all-wheel single lever system.

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MAINTENANCE AND LUBRICATION

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and

adjustment. Do not attempt to adjust tie rod alignment. All tie rod

adjustments should be performed by an authorized Polaris dealer.

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

The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a

straight-ahead position.

NOTE: The steering frog can be

used as an indicator of

whether the handlebars

are straight. The frog

should always point

straight back from the

steering post.

2. Place stands (1) in front of

the vehicle, perpendicular to

the rear tires. See

illustration.

3. Tie an elastic string around

the stands, making sure the

string just touches the side

surface of the rear tires on

each side of the vehicle and

goes around the stands in

front of the vehicle (2).

4. Measure the distance from

the string to the rim at the

front and rear of the front

rim (3). Rear measurement should be 1/16″ - 1/8″ (.2 to .3 cm)

more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer

for service.

Steering Assembly

The steering assembly of the ATV should be checked periodically for

loose nuts and bolts. If loose nuts and bolts are found, see your Polaris

dealer for service before operating the vehicle.

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MAINTENANCE AND LUBRICATION

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm

motion, pull the panel outward to disengage the side panel from the

grommet.

3. Pull the panel downward and rearward to remove it from the ATV.

4. Reinstall the side panel by reversing the removal procedure.

Footwell Removal

1. Remove the four screws (1)

on the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the

plastic rivets (2) securing the

footwell to the fenders.

3. Remove the footwell.

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MAINTENANCE AND LUBRICATION

WARNING

Operating your ATV with worn tires, improperly inflated tires,

non-standard tires or improperly installed tires will affect vehicle

handling and could cause an accident resulting in serious injury or

death.

Maintain proper tire pressure as described on the decal on your

ATV and in the owner’s manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Tire Tread Depth

1/8I (.3 cm)

Always replace tires when tread

depth is worn to 1/8″ (.3 cm) or less.

See illustration.

Wheel Removal

1. Stop the engine, place the transmission in

park and lock the parking brake.

2. Loosen the wheel nuts slightly.

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

footrest frame.

4. Remove the wheel nuts and remove the wheel.

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MAINTENANCE AND LUBRICATION

Wheel Installation

WARNING

Improperly installed wheels can adversely affect tire wear and

vehicle handling, which can result in serious injury or death.

Always ensure that all nuts are torqued to specification. Do not

service axle nuts that have a cotter pin installed. See your

Polaris dealer.

1. Place the transmission in park

and lock the parking brake.

2. Place the wheel on the

wheel hub with the valve stem

toward the outside and

rotation arrows on the tire

pointing toward forward

rotation.

3. Install the wheel nuts and finger

tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been

loosened for maintenance service.

Location

Torque

Front Wheel Nuts

Rear Wheel Nuts

27 ft. lbs. (37 Nm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical

component operations. All service must be performed by your

authorized Polaris dealer.

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MAINTENANCE AND LUBRICATION

Filter Systems

Air Filter Service

1. Remove the seat, release the air

box cover clips, and remove the

air box cover.

2. Loosen the clamp and remove the

filter.

3. Remove the fabric type pre-filter

(1) from the main filter (2). Wash

the pre-filter in soapy water, then

rinse and let dry.

4. Reinstall the pre-filter over the

main filter. (Replace the main

filter if needed.)

5. Reinstall the filter into the air box

and tighten the clamp. Do not

over tighten the clamp, as filter

damage could occur.

6. Reinstall the air box cover and the

seat.

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MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that

will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death.

Headlight and taillight lenses become dirty during normal

operation. Wash the headlights frequently to maintain lighting

quality.

Hot components can cause serious burns to skin. Allow lamps to

cool before servicing.

Headlight Lamp Replacement

1. Remove the two screws on the lower front corners of the headlight

pod.

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the

pod.

4. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

5. Unplug the headlamp from the wiring harness. Be sure to pull on

the connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp.

NOTE: Make sure the tab on the lamp locates properly in the

housing.

8. Reassemble the pod.

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MAINTENANCE AND LUBRICATION

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

Use the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight

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

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

and make a mark on the wall at the same height.

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

4. Observe the headlight aim on the wall. The most intense part of

the headlight beam should be two inches (5.1 cm) below the mark

on the wall.

NOTE: Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight

pod. Adjust the beam to the desired position by turning the knob

either clockwise or counterclockwise.

Low Beam Adjustment

The low beam can be adjusted

slightly upward or downward.

1. Loosen the phillips screw (2)

located at the rear of the

headlamp.

2. Tilt the headlamp upward or

downward.

3. Tighten the screw.

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MAINTENANCE AND LUBRICATION

Lights

Headlight Housing Replacement

1. Remove the two screws on the lower front corners of the headlight

pod.

2. Lift the pod slightly while depressing the tabs at the rear of the

pod.

3. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

4. Unplug the headlamp from the wiring harness.

5. Use a small screwdriver to remove the o-rings from the headlight

mounting tabs.

6. Pull the headlight housing up to release it from the locking tabs.

7. Lift the adjusting knob up to remove it from the locking tabs.

8. Carefully pull the assembly up and out of the pod.

9. Reverse the steps to install the new

housing and reassemble the pod.

NOTE: The distance from the

headlamp parting line to the

end of the adjustment knob

stop is 5 1/8″ (13 cm).

10. Adjust the headlight aim by

turning the adjusting knob.

5 1/8″

(13 cm)

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MAINTENANCE AND LUBRICATION

Lights

Lower Headlamp Removal / Installation

1. Turn the back of the headlight

harness (1) counterclockwise

and pull the harness assembly

away from the headlight

assembly.

2. Remove the headlamp and

install the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

4. Turn the headlight harness

clockwise to secure the

headlamp.

Taillight/Brakelight/Worklight Lamp Replacement

1. Remove the harness

connector (1) from the

back of the light assembly.

2. Turn the lamp (2)

counterclockwise to

remove it.

3. Apply dielectric grease to

the socket and install the

new lamp.

4. Reinstall the harness

connector.

5. Test the light for proper

operation.

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MAINTENANCE AND LUBRICATION

Spark Plugs

S Use RC7YC spark plugs.

S Proper electrode gap is .035″ (.90 mm).

S Spark plug torque is 18 ft. lbs. (24 Nm).

CAUTION

Using non-recommended spark plugs can result in serious engine

damage. Always use Polaris-recommended spark plugs.

Spark plug condition is indicative of engine operation. The spark plug

firing end condition should be read after the engine has been warmed

up and the vehicle has been driven at higher speeds. Immediately

check the spark plugs for correct color.

WARNING

A hot exhaust system and engine can cause serious burns. Wear

protective gloves when removing a spark plug for inspection.

1. Normal

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

combustion deposits. The electrodes are not burned or eroded. This

indicates the proper type and heat range for the engine and the service.

NOTE: The tip should not be flaky and white. A white insulator tip

indicates overheating, caused by use of an improper spark

plug or incorrect fuel.

2. Wet Fouled

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil,

use of non-recommended oil or incorrect throttle body adjustments.

Spark Plug Removal and Replacement

1. Remove the spark plug cap.

2. Using the special wrench provided in the tool pouch, rotate the

spark plug counterclockwise to remove.

3. Reverse the procedure for spark plug installation. Torque to 18 ft.

lbs. (24 Nm).

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MAINTENANCE AND LUBRICATION

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can

result if the machine is not thoroughly inspected. Take the

vehicle to your dealer before starting the engine.

If it’s impossible to take your ATV to a dealer before starting it, follow

the steps outlined below.

1. Move the ATV to dry land or at the very least, to water below the

footrests.

2. Check the air box for any water and dry it if it’s wet.

NOTE: Filter replacement is required if water is present.

3. Remove the spark plugs.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs and reinstall, or replace with new plugs.

6. Attempt to start the engine. If necessary, repeat the drying

procedure.

7. Take the ATV to your dealer for service as soon as possible,

whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT, follow the procedure

on page 93 for drying out the PVT.

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MAINTENANCE AND LUBRICATION

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark

arrestor could result in serious injury or death.

Do not perform service on the spark arrestor while the system is

hot. Exhaust system temperatures can reach 1000° F. Allow

components to cool sufficiently before proceeding.

Remove any combustible materials from the area. Wear eye

protection and leather work gloves. Do not stand behind or in

front of the vehicle while purging. Never run the engine in an

enclosed area. Exhaust contains poisonous carbon monoxide

gas. Never go under the vehicle while it’s inclined.

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe/mufflers.

1. Remove the arrestor clean-out

plugs (1) from the bottom

of the mufflers.

2. Place the transmission in

PARK and start the

engine.

3. Purge carbon from the

system by momentarily

revving the engine

several times.

4. If carbon is expelled, cover or

plug the exhaust outlets (2) and rap

on the pipes around the cleanout plugs

while revving the engine several more times.

5. If particles are still suspected to be in the mufflers, elevate the rear

of the vehicle one foot higher than the front. Set the parking brake

and block the wheels. Make sure the vehicle is in PARK and

repeat steps 3 and 4 until no more particles are expelled when the

engine is revved.

6. Stop the engine and allow the arrestors to cool. Reinstall the

arrestor plugs and remove the outlet covers or plugs.

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MAINTENANCE AND LUBRICATION

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the flyweights also

increases. This, in turn, increases the amount of pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of

centrifugal force decreases, reducing the amount of belt pinch.

On Polaris ATVs, the approximate gear ratio difference between high

and low range is 1:2.25. This difference in gearing affects the operation

of the PVT, especially at speeds less than 7 MPH (11 KPH), due to the

system’s dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 KPH) in

low range, the engine speed would be around 3000 RPM. This is well

above the engagement speed of 1200 - 1400 RPM. However, in high

range at 3 MPH (5 KPH), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the

engine may be running at a speed too low to provide the pinch needed

to prevent belt slip. Belt slip is responsible for creating the excessive

heat that destroys belts, wears clutch components and causes outer

clutch covers to fail.

By switching to low range while operating at low ground speeds, the

air temperature in the clutch cover is reduced by almost 160 degrees.

Reducing the temperature inside the clutch cover extends the life of the

PVT components (belt, cover, etc.).

When To Use Low Range vs. High Range

Following is a guideline for when to use low range and high range.

Low Range

S When basic operation is at speeds less than 7 MPH (11 KPH)

S For heavy pulling

S When operating in rough terrain (swamps, mountains, etc.) at low

ground speeds

High Range

S When basic operation is at speeds greater than 7 MPH (11 KPH)

S When operating at high ground speeds

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MAINTENANCE AND LUBRICATION

PVT System

WARNING

Failure to comply with the instructions in this warning can result in

severe injury or death.

Do not modify any component of the PVT system. Doing so may

reduce its strength so that a failure may occur at a high speed.

The PVT system has been precision balanced. Any modification

will cause the system to be out of balance, creating vibration and

additional loads on components.

The PVT system rotates at high speeds, creating large amounts

of force on clutch components. Extensive engineering and

testing has been conducted to ensure the safety of this product.

However, as the owner, you have the following responsibilities to

make sure this system remains safe:

Always follow all recommended maintenance procedures. See

your dealer as outlined in the owner’s manual.

This PVT system is intended for use on Polaris products only. Do

not install it in any other product.

Always make sure the PVT housing is securely in place during

operation.

PVT Drying

There may be some instances when water is accidently ingested into

the PVT system. Use the following instructions to dry it out before

operating:

1. Remove the drain plug and allow the water to drain. Replace the

drain plug.

2. Start the engine and shift the transmission into park. Apply varying

throttle for 10-15 seconds to expel the moisture and air-dry the belt

and clutches. Do not hold the throttle wide open for more than 10

seconds.

3. Allow the engine RPM to settle to idle speed, then shift the

transmission to the lowest available range.

4. Test for belt slippage. If the belt slips, repeat the process.

5. Take the vehicle to your dealer for service as soon as possible.

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MAINTENANCE AND LUBRICATION

Battery

WARNING

Improperly connecting or disconnecting battery cables can result

in an explosion and cause serious injury or death. When

removing the battery, always disconnect the negative (black)

cable first. When reinstalling the battery, always connect the

negative (black) cable last.

Battery Removal

1. Disconnect the battery hold-down strap.

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

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

4. Lift the battery out of the ATV.

Battery Installation

When installing a new battery, make sure it’s fully charged prior to its

initial use. Using a new battery that has not been fully charged can

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

vehicle performance. Follow the battery charging instructions on page

95 before installing the battery.

1. Ensure that the battery is fully charged.

2. Set the battery in the battery holder.

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

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

5. Attach the hold-down strap.

6. Verify that cables are properly routed.

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MAINTENANCE AND LUBRICATION

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it’s fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

NOTE: Battery charge can be maintained by using a Polaris Battery

Tendert charger (PN 2871076) or by charging about once a

month to make up for normal self-discharge. Battery

Tendert can be left connected during the storage period,

and will automatically charge the battery if the voltage drops

below a pre-determined point.

Battery Charging

The following battery charging instructions apply only to the

installation of a sealed battery. Read all instructions before proceeding

with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Do not ever pry the sealing strip off or

add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is

to keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2

amps or less until thebattery voltage is 12.8 or greater.

NOTE: When using an automatic charger, refer to the charger

manufacturer’s instructions for recharging. When using a

constant current charger, use the following guidelines for

recharging.

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.

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MAINTENANCE AND LUBRICATION

Battery

Battery Charging

NOTE: Always verify battery condition before and 1-2 hours after the

end of charging.

State of

Charge

Voltage

Action

Charge Time*

(Using constant current

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

12.5-12.8 volts

None, check at

3 mos. from date of

manufacture

None required

75%-100%

May need slight

charge, if no

charge given,

check in 3 months

3-6 hours

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

See page 107 for the part numbers of Polaris products.

Cleaning the ATV

Keeping your ATV clean will not only improve its appearance but it

can also extend the life of various components. With a few

precautions, your ATV can be cleaned much like an automobile.

Washing the ATV

The best and safest way to clean your ATV is with a garden hose and a

pail of mild soap and water. Use a professional type washing mitten,

cleaning the upper body first and the lower parts last. Rinse with water

frequently and dry with a chamois to prevent water spots.

NOTE: If warning and safety labels are damaged, contact your a

Polaris dealer for free replacement.

CAUTION

High water pressure may damage ATV components. Polaris

recommends washing the ATV by hand or with a garden hose

using mild soap.

Certain products, including insect repellants and chemicals, will

damage plastic surfaces. Do not allow these types of products to

come into contact with the ATV.

If a high pressure water system is used, exercise extreme caution to

avoid damaging wheel bearings, radiator, transmission seals, body

panels, brakes and warning labels. Grease all zerk fittings immediately

after washing, and allow the vehicle to run for a while to evaporate any

water that may have entered the engine or exhaust system.

Waxing the ATV

Your ATV can be waxed with any non-abrasive automotive paste wax.

Avoid the use of harsh cleaners since they can scratch the body finish.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

CAUTION

Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur. Never

start the engine during the storage period.

Clean the Exterior

Make necessary repairs and then clean the ATV thoroughly with mild

soap and warm water to remove all dirt and grime. Don’t use harsh

detergents or high pressure washers. Some detergents deteriorate rubber

parts. Use dish soap type cleaners only. High pressure washers may

force water past seals.

Stabilize the Fuel

Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris

Fuel Stabilizer. Follow the instructions on the container for the

recommended amount. (Carbon clean will also reduce the possibility of

bacterial growth in the fuel system.) Allow 15-20 minutes of operation

for the stabilizer to disperse through the fuel in the tank.

Oil and Filter

Warm the engine and change the oil and filter.

Air Filter / Air Box

Inspect and clean or replace the pre-cleaner and air filter. Clean the air

box and drain the sediment tube.

Fluid Levels

Inspect the following fluid levels and change if necessary: front and

rear gearcases; transmission and brake fluid (change every two years or

as required if fluid looks dark or contaminated).

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Storage Tips

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean, following the

instructions on the can. Run the engine for several minutes so the

Carbon Clean reaches the injectors. Turn the engine off.

2. Remove the spark plugs and add 2-3 tablespoons of Premium 4

Synthetic 0W40 engine oil. To access the plug holes, use a section of

clear 1/4” hose and a small plastic squeeze bottle filled with the

pre-measured amount of oil.

NOTE: Do this carefully! If you miss the plug holes, oil will drain from

the spark plug cavities into the hole at the front of the cylinder

head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to 18 ft. lbs. (24 Nm).

4. Apply dielectric grease to the inside of each spark plug cap and

reinstall the caps onto the plugs.

5. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protective

film of fresh oil.

6. If Polaris fuel system additive is not used, fuel tank, fuel lines, and

injectors should be completely drained of gasoline.

Inspect and Lubricate

Inspect all cables and lubricate. Follow lubrication guidelines in the

Maintenance Section of the service or owner’s manual to completely

grease and lubricate the entire vehicle with Polaris Premium All

Season Grease.

Battery Maintenance

Remove the battery and recharge it as outlined on page 95. Store the

battery in a cool, dry place.

Engine Anti-Freeze

Test engine coolant strength and change if necessary. Coolant should

be replaced every two years.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires 1-2” off

the ground. Be sure the storage area is well ventilated, and cover the

machine with a genuine Polaris ATV cover.

NOTE: Do not use plastic or coated materials. They do not allow

enough ventilation to prevent condensation, and may promote

corrosion and oxidation.

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MAINTENANCE AND LUBRICATION

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion,

preserve wheel life and ensure a “like new” appearance for many years.

1. Wash chrome rims frequently. Use a mild detergent to remove any

salt, dirt, mud or grime. Never use abrasive cleaners on plated or

painted surfaces.

2. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

3. Routinely and liberally apply a weather resistant wax to each

polished chrome wheel. Choose a product suitable for chrome

finishes. Read and follow the product labels and instructions.

4. Chrome wheels exposed to road salt (or salt in the air in coastal

areas) are more susceptible to corrosion if not properly cleaned.

Clean chrome wheels more often if they’re exposed to salt or other

corrosive elements.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT

grade) to remove it. Gently rub the affected areas with the steel wool

until the corrosion has been removed. Clean and polish the wheel as

outlined above.

Transporting the ATV

Follow these procedures when

transporting the vehicle.

1. Turn off the engine and remove

the key to prevent loss during

transporting.

2. Place the transmission in PARK

and lock the parking brake.

3. Turn the fuel valve off and be

sure the fuel cap, oil cap and

seat are installed securely.

4. Always tie the frame of the

ATV to the transporting unit

securely with suitable straps or

rope. Do not attach tie straps to

the front A-arm bolt pockets.

100

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ADJUSTMENTS

Camber and Caster

The camber and caster are non-adjustable.

Rear Spring

The rear shock absorber spring is

adjusted by rotating the adjuster (1)

either clockwise or

counterclockwise to increase or

decrease spring tension.

NOTE: Accessory springs are

available through your

Polaris dealer.

Handlebars

WARNING

Improper adjustment of the handlebars or incorrect torquing of

the adjuster block tightening bolts can cause limited steering or

loosening of the handlebars, resulting in loss of control and

possible serious personal injury or death. Follow the adjustment

procedures exactly, or see your Polaris dealer for service.

The handlebars can be adjusted for

rider preference.

1. Locate handlebar bolts (1) by

removing the upper headlight pod.

2. Loosen the four bolts.

3. Adjust the handlebar to the desired

height. Be sure the handlebars do not

contact the gas tank or any other part of

the machine when turned fully to the left or right.

4. Torque the front two bolts to 10-12 ft. lbs. (14-17 Nm), then torque

the rear two bolts. A gap of up to 1/8” will remain at the rear of

the clamp blocks.

101

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ADJUSTMENTS

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your Polaris dealer for adjustment.

Throttle Cable Freeplay

Throttle cable freeplay is adjusted at the handlebar.

1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen

the adjuster locknut (3).

2. Turn the adjuster until 1/16″ to 1/8″ freeplay is achieved at the

thumb lever.

NOTE: While adjusting freeplay, be sure to flip the throttle lever back

and forth.

3. Tighten the locknut and slide the boots over the cable adjuster until

they touch at the midpoint of the adjuster.

102

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TROUBLESHOOTING

Drive Belt and Cover Problems

Possible Cause

Solution

Driving the ATV onto a

pickup or tall trailer in

high range

Shift transmission to low range during loading of the ATV

to prevent belt burning.

Starting out going up a

steep incline

When starting out on an incline, use low range or dis-

mount the ATV (after first applying the park brake) and

perform the K-turn as described on page 58.

Driving at low RPM or

low ground speed (at

Drive at a higher speed or use low range more frequently.

The use of low range is highly recommended for cooler

approximately 3-7 MPH) PVT operating temperatures and longer component life.

Insufficient warm-up of Warm the engine at least 5 minutes. With the transmission

ATVs exposed to low am- in park, advance the throttle to about 1/8 throttle in short

bient temperatures

bursts, 5 to 7 times. The belt will become more flexible

and prevent belt burning.

Slow and easy clutch en- Use the throttle quickly and effectively for efficient enga-

gagement

gement.

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing snow, Use low range only.

dirt, etc.

Stuck in mud or snow

Shift the transmission to low range, and carefully use fast,

aggressive throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large ob-

Shift the transmission to low range, and carefully use fast,

jects from a stopped posi- brief, aggressive throttle application to engage clutch.

tion

WARNING: Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water Shift the transmission to park. Using the throttle, vary the

or snow ingestion into the engine RPM from idle to full throttle. Repeat several

PVT system

times as required. During this procedure, the throttle

should not be held at the full position for more than 10

seconds. Clutch seals should be inspected for damage if

repeated leaking occurs.

Clutch malfunction

Contact your Polaris dealer for inspection of clutch com-

ponents.

Poor engine performance Replace old or off-season fuel with fresh fuel. Check for

fouled plugs or foreign material in gas tank, fuel lines or

fuel filter. See your dealer for service.

103

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TROUBLESHOOTING

Contact your Polaris dealer for service if you’re unable to identify

solutions using the following charts.

Engine Doesn’t Turn Over

Possible Cause

Solution

Tripped circuit breaker

Low battery voltage

Reset the breaker

Recharge battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three

times for 5 seconds each, then start

Clogged fuel filter

Inspect and replace

Water is present in fuel

Drain the fuel system and refuel

Old, off-season or non-recommended fuel Replace with fresh fuel

Fouled or defective spark plugs

No spark to spark plug

Inspect plugs, replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your Polaris dealer

Recharge battery to 12.8 VDC

See your Polaris dealer

Crankcase filled with water or fuel

Low battery voltage

Mechanical failure

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your Polaris dealer

Set gap to specs or replace plugs

Incorrect spark plug gap or heat range

104

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TROUBLESHOOTING

Engine Backfires

Possible Cause

Solution

Weak spark from spark plugs

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with new fuel

See your Polaris dealer

Mechanical failure

Engine Runs Irregularly, Stalls or Misfires

Possible Weak Spark Cause

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Solution

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your Polaris dealer

Possible Lean Fuel Mixture Cause Solution

Low or contaminated fuel

Low octane fuel

Add or change fuel, clean the fuel system

Replace with recommended fuel

Replace filter

Clogged fuel filter

Possible Rich Fuel Mixture Cause Solution

Fuel is very high octane

Replace with lower octane fuel

Stopping/starting without adequate warm- Allow engine to warm up before operat-

ing and/or stopping

105

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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

Water present in fuel

Inspect and replace

Replace with new fuel

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Inspect, clean and/or replace spark plugs

See your Polaris dealer

Set gap to specs or replace plugs

Check all connections and tighten

Recharge battery to 12.8 VDC

Replace with recommended fuel

Inspect and clean or replace

See your Polaris dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your Polaris dealer

Clean radiator screen and core

Clean engine exterior

See your Polaris dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

106

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POLARIS PRODUCTS

Part No.

Description

Engine Lubricant

2870791

2871281

2871844

Fogging Oil (12 oz. Aerosol)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.)

Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lube (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Premium ATV Angle Drive Fluid (8 oz.)

Premium ATV Angle Drive Fluid (2.5 gal.)

Pump for Gallon Jug

2873602

2873603

2871653

2872276

2870465

2871654

2872277

Premium Demand Drive Hub Fluid (8 oz.)

Premium Demand Drive Hub Fluid (2.5 gal.)

Grease / Specialized Lubricants

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Grease Gun Kit

Dielectric Grease (Nyogelt)

Chain Lube (6.25 oz. aerosol)

Chain Lube (16 oz. aerosol)

2871322

2871423

2871460

2871515

2871551

2871312

2871329

2872073

2872348

Coolant

2871323

2871534

60/40 Coolant (gal.)

60/40 Coolant (qt.)

Additives / Miscellaneous

Brake and Clutch Cleaner

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT3 Brake Fluid

2872889

2871326

2870652

2870990

2872893

Engine Degreaser

107

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SPECIFICATIONS

SPORTSMAN 800 EFI

Gross Vehicle Weight

1240 lbs. (563 kg)

4.13 gal. (15.6 l)

2 qts. (1.9 l)

Fuel Capacity

Engine Oil Capacity

Rear Gearcase Oil Capacity

Front Gearcase Oil Capacity

Transmission Oil Capacity

Coolant Capacity

10 oz. (300 ml)

5 oz. (150 ml)

15 oz. (450 ml)

3.2 qts. (3 l)

Front Rack/Storage Box Capacity

Rear Rack Capacity

100 lbs. (45 kg)

200 lbs. (91 kg)

Receiver Hitch Tongue Capacity

150 lbs. (68 kg) (Combination of rear rack

weight and tongue weight not to exceed 200

lbs./91 kg)

Receiver Hitch Towing Capacity

Overall Length

1500 lbs. (681 kg)

83 in. (211 cm)

Overall Width

48 in. (122 cm)

Overall Height

48 in. (122 cm)

Wheelbase

50.75 in. (128.9 cm)

11.25 in. (28.5 cm)

770 lbs. (349 kg)

Ground Clearance

Dry Weight

Minimum Turning Radius

Engine

71.5 in. (182 cm) unloaded

EH0760LE011

Displacement

760 cc

Bore x Stroke

80 x 76

Alternator Output

Compression Ratio

Starting System

Fuel System

500 Watts @ 3000 rpm

10:1

Electric

Electronic Fuel Injection

ECU

Ignition System

Ignition Timing

Spark Plug / Gap

Lubrication System

Driving System Type

Front Suspension

Rear Suspension

8 BTDC @ 2000 RPM

RC7YC / .035 in. (0.9 mm)

Pressurized Wet Sump

4 Wheel Independent Shaft

MacPherson strut with 8.2” (21 cm) travel

Progressive rate with 9.5” (24 cm) travel

108

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SPECIFICATIONS

SPORTSMAN 800 EFI

Transmission

Automatic EBS w/E-Z Shift H/L/N/R/P

Gear Reduction (Low)

Gear Reduction (Reverse)

Gear Reduction (High)

Drive Ratio (Front)

Drive Ratio (Final)

Tires / Pressure (Front)

Tires / Pressure (Rear)

Brakes (Front)

7.49:1

5.11:1

2.70:1

3.82:1

3.10:1

Polaris PXT 26 x 8 - 12 / 5 psi

Polaris PXT 26 x 11 - 12 / 5 psi

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc

Hydraulic lock, all wheel

Brakes (Rear)

Brakes (Auxiliary)

Brake (Parking)

Headlight

1 - Single Beam on Handlebar (50 watt)

2 - Single Beam on Grill (27 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Clutching Chart

Altitude

Shift

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

EBS

Weight

Meters

(Feet)

0-1800

(0-6000)

20-60

Blue/Green

PN 5631689 PN 7041157 PN 3234233 PN 3234234

1800-3700

(6000-12000)

20-58

Blue/Green

EBS

PN 5631216 PN 7041157 PN 3234233 PN 3234234

EBS models require no helix / spring adjustment

109

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WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX

MONTH LIMITED WARRANTY on all components of the Polaris All

Terrain Vehicle (ATV) against defects in material or workmanship.

Polaris also gives a one year limited warranty on the final drive chain

for failure due to defects. This warranty covers the parts and labor

charges for repair or replacement of defective parts which are covered

by this warranty. This warranty begins on the date of purchase. This

warranty is transferrable to another consumer during the warranty

period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed

by your dealer and submitted to Polaris within ten days. Upon receipt

of this registration, Polaris will record the registration for warranty.

THE PURCHASER MUST COMPLETE AN ATV SAFETY

TRAINING COURSE PROVIDED BY THE DEALER IN ORDER

TO HAVE VALID WARRANTY ON THE ATV. No verification of

registration will be sent to the purchaser as the copy of the Warranty

Registration Form will be the warranty entitlement. If you have not

signed the original registration and received the customer copy, please

contact your dealer immediately. NO WARRANTY COVERAGE

WILL BE ALLOWED UNLESS YOUR ATV IS REGISTERED

WITH POLARIS.

Initial dealer preparation and set-up of your ATV is very important in

ensuring trouble-free operation. Purchasing a machine in the crate or

without proper dealer set-up will void your warranty coverage.

110

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused

by a defect in material or workmanship. This warranty does not cover

accidental damage, normal wear and tear, abuse or improper handling.

This warranty also does not cover any ATV that has been altered

structurally, modified, neglected, improperly maintained, used for

racing, or used for purposes other than for which it was manufactured,

or for any damages which occur during trailer transit or as a result of

unauthorized service or the use of unauthorized parts. In addition, this

warranty does not cover physical damage to paint or finish, stress

cracks, tearing or puncturing of upholstery material, corrosion, or

defects in parts, components or the ATV due to fire, explosions or any

other cause beyond Polaris’ control.

This warranty does not cover the use of unauthorized lubricants,

chemicals, or fuels that are not compatible with the ATV. The

exclusive remedy for breach of this warranty shall be, at Polaris’

exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS

WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY

PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL

HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,

CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR

IMPLIED WARRANTY OR ANY OTHER CONTRACT,

NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some states

do not permit the exclusion or limitation of incidental or consequential

damages or implied warranties, so the above limitations or exclusions

may not apply to you if inconsistent with controlling state law.

111

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WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED

TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND

FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN

DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD.

POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES

NOT STATED IN THIS WARRANTY. Some states do not allow

limitations on how long an implied warranty lasts, so the above

limitation may not apply to you if inconsistent with controlling state

law.

HOW TO OBTAIN WARRANTY SERVICE

If your ATV requires warranty service, you must take it to a Polaris

dealer authorized to repair Polaris ATVs. When requesting warranty

service you must present your copy of the Warranty Registration form

to the dealer. (THE COST OF TRANSPORTATION TO AND FROM

THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that

you use your original selling dealer; however, you may use any Polaris

Servicing Dealer to perform warranty service.

Please work with your dealer to resolve any warranty issues. Should

your dealer require any additional assistance they will contact the

appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also have

other rights which vary from state to state.

If any of the above terms are void because of state or federal law, all

other warranty terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine

damage. We recommend the use of Polaris engine oil for your ATV.

2. Damage resulting from the use of non-recommended lubricants may

not be covered by warranty.

112

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE

IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON

THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE

SELLING DEALER’S AUTHORIZED LOCATION.

This policy does not apply to vehicles that have received authorization

for export from Polaris Industries. Dealers may not give authorization

for export. You should consult an authorized dealer to determine this

vehicle’s warranty or service bulletin coverage if you have any ques-

tions.

This policy does not apply to vehicles registered to government offi-

cials or military personnel on assignment outside the country of the

selling dealer’s authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized

Polaris dealer. If you move or 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 be-

fore you move. Vehicles importation rules vary considerably from

country to country. You may be required to present documentation of

your move to Polaris Industries in order to continue your warranty cov-

erage. You may also be required to obtain documentation from Polaris

Industries in order to register your vehicle in your new country.

113

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WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the

country in which the vehicle was originally purchased, all warranty

coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was pur-

chased, and you have not followed the procedure set out above, your

vehicle will no longer be eligible for warranty or service bulletin cover-

age of any kind. (Vehicles registered to Government officials or mili-

tary personnel on assignment outside of the country where the vehicle

was purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-763-417-8650

Canada: 1-204-925-7100

114

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INDEX

Accessories . . . . . . . . . . . . . . . . . . . 64

ADJUSTMENTS . . . . . . . . . . 101-102

Age Restrictions . . . . . . . . . . . . . . . 11

Air Filter Service . . . . . . . . . . . . . . . 84

All Wheel Drive . . . . . . . . . . . . . . . 39

Automatic Transmission . . . . . . . . . 38

Auxiliary Brake . . . . . . . . . . . . . . . 79

AWD . . . . . . . . . . . . . . . . . . . . . . . . 39

Engine Cooling System . . . . . . . . . 76

Engine Stop Switch . . . . . . . . . . . . 32

Equipment Modifications . . . . . . . . 15

Exhaust Emission Control System . 63

FEATURES . . . . . . . . . . . . . . . . 32-45

Filter Systems . . . . . . . . . . . . . . . . . 84

Footwell Removal . . . . . . . . . . . . . . 81

Front Gearcase Oil . . . . . . . . . . . . . 74

Front Wheel Hub Tightening . . . . . 83

Fuel Filter . . . . . . . . . . . . . . . . . . . . 37

Fuel Safety . . . . . . . . . . . . . . . . . . . 46

Fuel Tank . . . . . . . . . . . . . . . . . . . . 37

Battery . . . . . . . . . . . . . . . . . . . . 94-96

Battery Charging . . . . . . . . . . . . . 95-96

Battery Installation . . . . . . . . . . . . . 94

Battery Removal . . . . . . . . . . . . . . . 94

Battery Storage . . . . . . . . . . . . . . . . 95

Belt Life . . . . . . . . . . . . . . . . . . . . . 38

Brake Fluid . . . . . . . . . . . . . . . . 35, 37

Brake Lever . . . . . . . . . . . . . . . . . . 34

Brake, Auxiliary . . . . . . . . . . . . . . . 37

Brakelight . . . . . . . . . . . . . . . . . . . . 88

Brakes . . . . . . . . . . . . . . . . . . . . . 78-79

Break-In Period . . . . . . . . . . . . . . . . 47

Gear Selector . . . . . . . . . . . . . . . . . . 38

Handlebars . . . . . . . . . . . . . . . . . . 101

Hauling Cargo . . . . . . . . . . . . . . . 50-51

Headlight Housing Replacement . . . 87

Headlight Lamp Replacement . . . . . 85

High Beam Adjustment . . . . . . . . . . 86

High Range . . . . . . . . . . . . . . . . . . . 92

Hour Meter . . . . . . . . . . . . . . . . . . . 42

Camber and Caster . . . . . . . . . . . . 101

Chrome Wheel Care . . . . . . . . . . . 100

Cleaning . . . . . . . . . . . . . . . . . . 97-100

Clutching Chart . . . . . . . . . . . . . . . 109

Cold Weather Operation . . . . . . . . . 49

CONTROLS . . . . . . . . . . . . . . . . 32-45

Coolant Level . . . . . . . . . . . . . . . . . 77

Cooling System . . . . . . . . . . . . . . . 77

Cooling System Operation . . . . . . . 77

Corrosion . . . . . . . . . . . . . . . . . . . 100

Crankcase Emission Control System 63

Idle RPM . . . . . . . . . . . . . . . . . . . 102

Instrument Cluster . . . . . . . . . . . . 40-45

K-Turn . . . . . . . . . . . . . . . . . . . . . . 58

Light Switches . . . . . . . . . . . . . . . . 34

Lights . . . . . . . . . . . . . . . . . . . . . 85-88

Low Beam Adjustment . . . . . . . . . . 86

Low Range . . . . . . . . . . . . . . . . . . . 92

Lower Headlamp . . . . . . . . . . . . . . 88

Lubrication Guide . . . . . . . . . . . . . . 69

Diagnostic Mode . . . . . . . . . . . . . 43-45

Driving in Reverse . . . . . . . . . . . . . 61

Driving on Slippery Surfaces . . . . . 54

Driving Over Obstacles . . . . . . . . . . 60

Driving Procedures . . . . . . . . . . . . . 52

Driving Safely . . . . . . . . . . . . . . . 52-62

Driving Through Water . . . . . . . . . . 59

Main Switch . . . . . . . . . . . . . . . . . . 32

MAINTENANCE AND

LUBRICATION . . . . . . . . 64-100

Maintenance Record . . . . . . . . . . . . 68

Making Turns . . . . . . . . . . . . . . . . . 53

Master Cylinder . . . . . . . . . . . . . . . 35

Electrical Switches . . . . . . . . . . . . . 32

EMISSION CONTROL SYSTEMS 63

Engaging Front Gearcase . . . . . . . . 39

115

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INDEX

Noise Emission Control System . . . 63

Starting the Engine . . . . . . . . . . . . . 49

Steering Assembly . . . . . . . . . . . . . 80

Storage . . . . . . . . . . . . . . . . . . . 97-100

Storage Tips . . . . . . . . . . . . . . . . 98-99

Switches . . . . . . . . . . . . . . . . . . . . . 32

Stop Switch . . . . . . . . . . . . . . . . . . . 32

Symbols . . . . . . . . . . . . . . . . . . . . . 12

Odometer . . . . . . . . . . . . . . . . . . . . 42

Oil Change . . . . . . . . . . . . . . . . . . . 72

Oil Filter Change . . . . . . . . . . . . . . 72

Oil Level . . . . . . . . . . . . . . . . . . . . . 71

OPERATION . . . . . . . . . . . . . . . 46-62

Operator Safety . . . . . . . . . . . . . . 11-31

Override Switch . . . . . . . . . . . . . . . 32

TABLE OF CONTENTS . . . . . . . . .

Tachometer . . . . . . . . . . . . . . . . . . . 42

Taillight . . . . . . . . . . . . . . . . . . . . . . 88

Throttle Body . . . . . . . . . . . . . . . . 102

Throttle Cable Freeplay . . . . . . . . . 102

Throttle Lever . . . . . . . . . . . . . . . . . 33

Tires . . . . . . . . . . . . . . . . . . . . . . . . 82

Toe Alignment . . . . . . . . . . . . . . . . 80

Transmission Gear Selector . . . . . . . 38

Transmission Oil . . . . . . . . . . . . . . . 73

Transporting the ATV . . . . . . . . . . 100

Traveling Downhill . . . . . . . . . . . . . 57

Traveling Uphill . . . . . . . . . . . . . . . 55

Trip Meter . . . . . . . . . . . . . . . . . . . . 42

TROUBLESHOOTING . . . . . 103-106

Turning Around on a Hill . . . . . . . . 58

Parking Brake . . . . . . . . . . . . . . . . . 36

Parking on an Incline . . . . . . . . . . . 62

Periodic Maintenance Chart . . . . 64-67

POLARIS PRODUCTS . . . . . . . . 107

Pre Ride Inspection . . . . . . . . . . . . . 48

Premium 4 Synthetic Lubricant . . . . 70

PVT Drying . . . . . . . . . . . . . . . . . . 93

PVT System . . . . . . . . . . . . . . . . 92-93

Radiator Coolant Level . . . . . . . . . . 76

Rear Gearcase Oil . . . . . . . . . . . . . . 75

Rear Spring . . . . . . . . . . . . . . . . . . 101

Reverse Override Switch . . . . . . . . . 32

Rider Information Center . . . . . . 41-45

VEHICLE IDENTIFICATION

NUMBERS . . . . . . . . . . . . . . . .

Safe Riding Gear . . . . . . . . . . . . . . . 10

SAFETY . . . . . . . . . . . . . . . . . . . . 6-31

Safety Decals and Locations . . . . . . 6-9

Safety Training . . . . . . . . . . . . . . . . 11

Setting the Parking Brake . . . . . . . . 36

Side Panel Removal . . . . . . . . . . . . 81

Sidehilling . . . . . . . . . . . . . . . . . . . 56

Signal words . . . . . . . . . . . . . . . . . . 12

Spark Arrestor . . . . . . . . . . . . . . 63, 91

Spark Plugs . . . . . . . . . . . . . . . . . . . 89

SPECIFICATIONS . . . . . . . . . 108-109

Vehicle Immersion . . . . . . . . . . . . . 90

WARRANTY . . . . . . . . . . . . . 110-114

WELCOME . . . . . . . . . . . . . . . . . . .

Wheel Installation . . . . . . . . . . . . . . 83

Wheel Nut Torque Specifications . . 83

Wheel Removal . . . . . . . . . . . . . . . 82

Worklight . . . . . . . . . . . . . . . . . . . . 88

Worklight Switch . . . . . . . . . . . . . . 32

116

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