Polaris Offroad Vehicle 400 HO User Manual

WELCOME

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

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

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

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

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the Polaris Service Manual and should be

performed only by a Factory Certified Master Service Dealer (MSD)

Technician.

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

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

vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces-

sories, available through our online store at www.purepolaris.com. Have

your accessories and clothing delivered right to your door!

Download from Www.Somanuals.com. All Manuals Search And Download.

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 34

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Emission Control Systems . . . . . . . . . . . . . . . 67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 117

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 121

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 122

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 126

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Download from Www.Somanuals.com. All Manuals Search And Download.

KNOW YOUR VEHICLE

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

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

and understand your owner's manual, which includes valuable informa-

tion about all aspects of your vehicle, including safe operating proce-

dures.

Vehicle Identification Numbers

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

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

ignition key can be duplicated only by ordering a Polaris key blank

(using your key number) and mating it with one of your existing keys.

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

VIN

Engine Serial Number

####

Key Number

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

General Warning

WARNING

Improper ATV use can result in

SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED

HELMET AND PROTECTIVE

GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR

ALCOHOL

NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills or the conditions

• on public roads - a collision can occur with another vehicle

• with a passenger - passengers affect balance and steering and increase risk

of losing control

ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough ter-

rain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A

REPLACEMENT.

7172560

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Discretionary Warning

WARNING

• Never operate this ATV on

HILLS steeper than 25 degrees

25°. To prevent flip-over on

hilly terrain, when going up or

down, use throttle and brakes

gradually.

• REVERSE operation can be

dangerous even at low speeds.

Steering becomes difficult. To

prevent flipover, avoid sudden

braking or sharp turns.

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of

control, never activate override button with open throttle.

• PARKING BRAKE may relax when used for more than 5 minutes. When park-

ing on grades, leave shift in forward.

7172665

Tire Pressure/Load Warning

WARNING

IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of control

resulting in SEVERE INJURY OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT

5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY 365

LBS. (166 KG)

INCLUDES WEIGHT OF OPERATOR,

CARGO, AND ACCESSORIES

Reduce speed and allow greater distance for braking when carrying cargo.

Overloading or carrying tall, off-center, or unsecured loads will increase your risk

of losing control. 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Age 16 Warning

Rack

Warning

Rack

Warning

“No Passenger”

Warning

“No Passenger” Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7172566

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death.

NEVER operate this ATV if you are under age 16.

7172559

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safety Decals and Locations

Rack Warning, Front and Rear

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

• Max Rack Loads: Front 70 lbs. (32 kg) Rear 100 lbs. (46 kg)

7173740

Reverse Override Warning

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.

7172564

All Wheel Drive Switch

Do not push switch to engage AWD if the rear wheels are spinning. This may

cause severe drive shaft and clutch damage. See your Owner's Manual.

7079780

Hitch Capacity Label

TRAILER MAX WEIGHT:

750 LBS. (340 KG) ON LEVEL GROUND

HITCH MAX. VERTICAL WEIGHT: 75 LBS. (34 KG)

7173739

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective

clothing for comfort and to reduce the chance of injury.

Eye Protection

Long

Sleeves

Helmet

Gloves

Long Pants

Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety standards.

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

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever riding a Polaris vehicle, always wear shatterproof goggles or use a

shatterproof helmet face shield. Polaris recommends wearing approved

Personal Protective Equipment (PPE) bearing markings such as VESC

8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

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

protection.

Boots

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

Clothing

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

Riding pants with kneepads and a jersey with shoulder pads provide the

best protection.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 han-

dles 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased

your new ATV, your dealer instructed you on the authorized ATV

RiderCourse^smavailable to you and your eligible family members. This

training is included in the purchase price of your ATV. Polaris strongly

encourages you and your eligible family members who will be riding

the ATV to take the ATV RiderCourse^sm. You were also provided with

printed materials that explain safe operating procedures. You should

review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse^smby calling ATV Enrollment Express at (800) 887-2887 or

by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be

charged for this training.

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

and regulations concerning the operation of this vehicle in your area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your

vehicle are thoroughly inspected at specific intervals.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual

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

bols are used. Become familiar with their meanings before reading the

manual.

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

potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious

injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor

injury or damage to the vehicle.

CAUTION

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

NOTE

A note will alert you to important information or instructions.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

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

procedures described.

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

course. Purchasers of a new Polaris ATV and their eligible family

members are entitled to take the ATV RiderCourse^sm. Contact ATV

Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for

information on enrollment in the ATV RiderCourse^sm.

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

• Never permit a guest to operate the ATV unless the guest has read this

manual and all product labels and has completed a certified safety

training course.

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

walks, driveways, parking lots, and streets.

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

dirt or gravel road.

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

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

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

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

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

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

• Never attempt wheelies, jumps or other stunts.

• Always inspect your ATV before each use to make sure it's in safe

operating condition. Always follow the inspection and maintenance

procedures and schedules outlined in your owner's manual.

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

rests of the ATV during operation.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

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

miliar terrain. Be alert to changing terrain conditions.

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

• Always follow proper turning procedures as described in this manual.

Practice turning at low speeds before attempting to turn at faster

speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's

been involved in an accident.

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

Practice on smaller hills before attempting larger hills.

• Always follow proper procedures for climbing hills. Check the terrain

carefully before ascending a hill. Never climb hills with excessively

slippery or loose surfaces. Shift your weight uphill. Never open the

throttle suddenly or make sudden gear changes. Never go over the top

of a hill at high speed.

• Always follow proper procedures for going downhill and for braking

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

your weight uphill. Never go down a hill at high speed. Avoid going

down a hill at an angle, which would cause the vehicle to lean sharply

to one side. Drive straight downhill.

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

hills with excessively slippery or loose surfaces. Shift your weight

uphill. Never attempt to turn the ATV around on any hill until you've

mastered (on level ground) the turning technique outlined in this

manual. Avoid crossing the side of a steep hill when possible.

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

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

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

cedure for braking described in this manual. Always dismount on the

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

the ATV around and remount following the procedure described in

this manual.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

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

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

Always follow proper procedures when operating over obstacles as

described in this manual.

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

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

ding or sliding out of control.

• Avoid 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.

• Wet brakes may have reduced stopping ability. Test the brakes after

leaving water. If necessary, apply them lightly several times to allow

friction to dry out the pads.

• Always check for obstacles or people behind the ATV before operat-

ing in reverse. When it's safe to proceed in reverse, move slowly and

avoid turning at sharp angles.

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

always maintain proper tire pressure.

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

sories.

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

properly distributed and securely attached. Reduce speed and follow

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

greater distance for braking.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

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

www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-

3764.

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) mow-

ers, blades, tires, sprayers, or large racks, may change the handling

characteristics of the vehicle. Use only Polaris-approved accessories,

and familiarize yourself with their function and effect on the vehicle.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV without proper instruction.

WHAT CAN HAPPEN

The risk of an accident is greatly increased if the

operator does not know how to operate the ATV

properly in different situations and on different

types of terrain.

HOW TO AVOID THE HAZARD

Beginning and inexperienced operators should

complete the ATV RiderCourse^smoffered by

Polaris through the SVIA. They should then reg-

ularly practice the skills learned in the course and the operating techniques

described in the Owner's Manual.

For more information about the ATV RiderCourse^smcontact ATV Enrollment

Express at (800) 887-2887 or visit www.atvsafety.org.

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 oper-

ates an ATV.

Even though a child may be within the recom-

mended age group for operating some ATVs,

he/she may not have the skills, abilities, or judg-

ment 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Carrying a passenger on an ATV.

WHAT CAN HAPPEN

Carrying a passenger greatly reduces the oper-

ator'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. Operat-

ing 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating the ATV after consuming alcohol or

drugs.

WHAT CAN HAPPEN

Consumption of alcohol and/or drugs could seri-

ously affect operator judgment. Reaction time

may be slower and operator balance and per-

ception 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

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.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

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 contact the rear wheels and

lead to accident or injury.

HOW TO AVOID THE HAZARD

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

the ATV during operation.

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 oper-

ating on unfamiliar terrain. Always be alert to

changing terrain conditions.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Failure to use extra caution when

operating on excessively rough, slip-

pery or loose terrain.

WHAT CAN HAPPEN

Operating on excessively rough, slip-

pery or loose terrain could cause loss

of traction or loss of control, which

could result in an accident or over-

turn.

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.

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 attempt-

ing to turn at faster speeds.

Never turn at excessive speed.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating on excessively steep hills.

WHAT CAN HAPPEN

The vehicle may overturn.

HOW TO AVOID THE HAZARD

Never operate on hills too steep for the ATV or

for your abilities. Never operate the ATV on hills

steeper than 25 degrees.

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 degrees.

Never climb hills with excessively slippery or loose surfaces.

Shift your weight forward.

Never open the throttle suddenly while traveling uphill. The ATV could flip

over backwards.

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

another vehicle or person could be on the other side of the hill.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 59.

Always check the terrain carefully before descending a hill.

Shift your weight rearward.

Never travel down a hill at high speed.

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

sharply to one side. Travel straight down the hill when possible.

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 man-

ual. See page 60. Use extra caution when turn-

ing 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Stalling, rolling backwards or improperly dis-

mounting 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 60.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 pro-

cedures 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 recom-

mended maximum depth (see page

62), 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD

Operating this ATV with improper tires,

or with improper or uneven tire pres-

sure.

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 Indus-

tries Inc. or equivalent components designed for use on this ATV and should

be installed and used according to approved instructions. See your autho-

rized Polaris ATV dealer for more information.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 dis-

tance 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 phys-

ical skills. Persons with cognitive or physical disabilities who operate this

vehicle have an increased risk of overturn and loss of control, which could

result in severe injury or death.

WARNING

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause serious burns and fire. Do not touch hot exhaust

system components. Always keep combustible materials away from the

exhaust system. Use caution when traveling through tall grass, especially dry

grass.

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle

resulting in serious injury or death. Always remove the ignition key when the

vehicle is not in use.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Switches

Headlight

Switch

Main Key Switch

Engine

Stop Switch

Mode/Reverse

Override

All Wheel Drive

Switch

WARNING

Activating the override switch while the throttle is open can cause loss of con-

trol, resulting in severe injury or death. Do not activate the override switch

while the throttle is open.

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain

additional power while backing, depress the override switch.

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

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

through the modes of the rider information center. See page 44.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Switches

Engine Stop Switch

Move the stop switch either left

or right to the OFF position to

stop the engine quickly. The

engine will not start or run when

the switch is off.

OFF

RUN

OFF

NOTE: Both the main switch and the engine stop switch will shut off all electri-

cal power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 50 for starting pro-

cedures.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the

lights from high beam to low beam.

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

engine stop switch is in the RUN position.

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.

All Wheel Drive Switch

See page 43 for all wheel drive information.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Throttle Lever

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.

Engine speed and vehicle move-

ment are controlled by pressing the

throttle lever. 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 sys-

tem or replace it with any after market throttle mechanisms. Always ensure

that the throttle cable is properly installed to the ETC.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the

handlebar to apply the front and

rear brakes. These brakes are

hydraulically activated disc type

brakes that are activated by only

one lever.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess

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

which must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an acci-

dent and serious injury or death. Always check to be sure the parking brake

is disengaged before operating.

Locking the Parking Brake

1. Place the transmission in

gear.

2. Squeeze and release the brake

lever two or three times, then

squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

Important Safeguards

• The parking brake may relax if left on for a long period of time.

Always block the wheels to prevent rolling.

• Always block the wheels on the downhill side of the ATV if leaving it

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

tion.

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

hill. Always block the wheels to prevent rolling.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Auxiliary Foot Brake

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

main brake system. Should the main system fail, use the auxiliary foot

brake.

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 side-

ways, causing loss of control and serious injury or death.

The auxiliary foot brake is

located on the inside of the

right footrest. Operate this

brake with your right foot.

NOTE: If the rear wheels slide

while using the auxiliary

brake, reduce brake

pedal pressure to brake

the rear wheels without

skidding.

Auxiliary Foot Brake

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

See page 87.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Choke

The choke assists in starting a cold engine. Refer to the engine starting

procedure on page 50 for correct choke and throttle settings during start-

ing.

Fuel Tank Cap

Remove the fuel tank cap to

Fuel Tank

Cap

add fuel to the fuel tank. Use

either leaded or unleaded gaso-

line with a minimum pump

octane number of 87=(R+ M/2)

octane. Do not use E-85 fuel.

Fuel Valve

The fuel valve is located on the

bottom of the fuel tank. Access

the fuel valve through the right

side panel.

ON: For normal operation.

OFF: For vehicle storage and

when transporting.

Refuel when the instrument

gauge indicates a low fuel

level.

OFF

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100

hours of operation or annually. Do not attempt to clean the fuel filter.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear

selector is located on the

right side of the vehicle.

Gear

Selector

H: High Gear

N: Neutral

R: Reverse

Whenever the ATV is left

unattended, always place

the transmission in gear

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Recoil Starter

If the battery is too weak to start

Handle

Recoil Starter

the engine, use the recoil starter.

Follow the starting procedures on

page 50, cranking the engine with

the recoil starter instead of the

main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slowly so you can feel

the engine strokes.

NOTE: The rope will be harder to pull when the engine is on a compression

stroke. When a compression stroke is found, continue pulling the rope

just until the engine rolls past the stroke, then stop pulling immediately.

3. Allow the recoil rope to rewind into the recoil assembly, then pull

the rope abruptly and forcefully to start the engine.

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

CAUTION

Extending the recoil starter rope until it stops can cause damage to the recoil

assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil

housing and damage components. Make sure the handle is fully seated on

the recoil housing, especially when traveling in wet areas.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The All Wheel Drive system is

controlled by the AWD switch.

When the switch is on 2X4, the

ATV is in two-wheel drive at all

times. When the switch is on

AWD, the ATV is in all wheel

drive.

AWD

Switch

When in AWD, the demand drive

unit will automatically engage

any time the rear wheels lose traction. When the rear wheels regain trac-

tion, the demand drive unit will automatically disengage.

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

switch is on. See page 34.

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

Engaging AWD

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

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

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

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

while the demand drive unit is moving, it will not disengage until the

rear wheels regain traction.

Engage the AWD switch before getting into conditions where front

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

throttle before switching to AWD.

CAUTION

Switching to AWD while the rear wheels are spinning may cause severe drive

shaft and gearcase damage. Always switch to AWD while the rear wheels

have traction or are at rest.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 34 for additional

information.

CAUTION

High water pressure may damage ATV components. Wash the ATV by hand

or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the

speedometer lens and other plastic surfaces. Do not use alcohol to clean the

instrument cluster. Do not allow insect sprays to contact the lens. Immedi-

ately clean off any gasoline that splashes on the instrument cluster.

Miles/Kilometers Toggle

The display in the tripmeter, odometer and speedometer can be changed

to display either kilometers or miles.

1. To change modes, press and release the mode button (see page 31)

as often as needed to reach the odometer mode.

2. In the odometer mode, press and hold the mode button until the let-

ters flash, then release the button.

3. Press and release the button one more time. When the display stops

flashing, the mode has been set.

Download from Www.Somanuals.com. All Manuals Search And Download.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

ments will light up for 3 seconds at start-up.

1. Gear Indicator - This

indicator displays gear

shifter position.

N = Neutral (Green)

R = Reverse (Amber)

2. Engine Hour Display

Indicator

3. Speedometer

4. Odometer/Tripmeter/

Hour Meter

Modes

Use the reverse override/mode

button to toggle through the 3

standard modes.

NOTE: If using the mode button to program the rider information center, or to

toggle through the options, the transmission cannot be in reverse.

Odometer

The odometer records the distance traveled by the ATV.

Trip Meter

The trip meter records the distance traveled by the ATV on each trip if

it's reset before each trip. To reset the trip meter, toggle to the trip meter

mode. Press and hold the mode button until the display changes to 0.

In the Rider Information Center, the trip meter display contains a deci-

mal point, but the odometer displays without a decimal point.

Hour Meter

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

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

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

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is the first ten hours of

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

No single action on your part is as important as following the proce-

dures for a proper break-in. Careful treatment of a new engine and drive

components will result in more efficient performance and longer life for

these components.

CAUTION

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

close-fitted engine parts and drive components. Do not operate at full throttle

or high speeds during the first three hours of use.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 40.

2. Check the oil level on the dipstick. See page 75. Add oil if neces-

sary to maintain the level between the safe and add marks.

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

iarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 49.

6. Pull only light loads.

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

hours.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life

and better performance. Break in the clutches and belt by operating at

slower speeds during the break-in period as recommended. Pull only

light loads. Avoid aggressive acceleration and high speed operation dur-

ing the break-in period.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Pre-Ride Checklist

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.

Item

Remarks

Page

Brake system/lever travel

Ensure proper operation

Brake fluid

Ensure proper level

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

Wheels/fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level (if applicable)

Ensure proper level

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

120

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 approved helmet, goggles, and

protective clothing

Download from Www.Somanuals.com. All Manuals Search And Download.

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.

2. Place the transmission in neutral.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the trans-

mission is in gear and the brake is not engaged.

4. Turn the fuel valve on.

5. Sit on the vehicle.

NOTE: Do not use the choke if starting a warm engine. Excessive use of the

choke can cause the spark plug to become wet fouled.

6. If the engine is cold, pull the

choke knob out until it stops.

NOTE: The variable choke is fully

on when the knob is pulled

completely out. The choke

is off when the knob is

pushed completely in. The

choke can be adjusted

gradually, depending on

how much choke is needed

for starting. Be sure the

choke is off during opera-

Choke

tion, as excess fuel wash-

Knob

ing into the engine oil will

increase wear on engine

components.

7. Move the engine stop switch to RUN.

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

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Starting the Engine

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

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

key when the engine starts.

9. If the engine does not start, return the key to the OFF position and

wait five seconds before attempting to start again. Activate the

starter for another five seconds if necessary. Repeat this procedure

until the engine starts.

NOTE: If a warm engine has cooled to a point where it does not readily start,

intermittent use of the choke button (pulled half way out) may be nec-

essary. If the engine is over-choked when warm, depress the throttle

lever fully while cranking to aid in starting. Release the throttle lever

immediately after the engine starts. If the engine does not start and all

conditions are favorable, change the spark plug and try again.

10. If the engine slows or stops, position the choke knob half way in to

allow proper engine warm up. Vary the engine RPM slightly with

the throttle to aid in warm-up. When the engine idles smoothly,

push the choke completely in.

CAUTION

Operating the vehicle immediately after starting could cause engine damage.

Allow the engine to warm up for several minutes before operating the vehicle.

Cold Weather Operation

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

level could indicate the accumulation of contaminates such as water or

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

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

mulation increases as outside temperature decreases.

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

warm-ups and easier starting in colder weather.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Hauling Cargo

2/3

1/3

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 specifi-

cations section of the owner's manual and on the safety decals.

Cargo weight should be evenly distributed (1/3 on the front rack and 2/3

on the rear rack) and mounted as low as possible. When operating over

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

driving conditions. Do not obstruct the headlight beam with cargo.

Towing Loads

Always attach a towed load to the hitch point. If towing a load, reduce

rear rack cargo weight by the amount of tongue weight. The combina-

tion of rear rack cargo weight and tongue weight must not exceed the

rear rack capacity.

CAUTION

Using an improper hitch or exceeding the

maximum tongue weight capacity can

result in serious damage to the vehicle

and will void your ATV warranty. Never

install a hitch longer than 6 3/4" (17 cm).

Never install automotive accessories on

your Polaris ATV. Always install Polaris-

approved (or equivalent) accessories

designed for ATV use.

Maximum

6 3/4" (17 cm)

Download from Www.Somanuals.com. All Manuals Search And Download.

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 only one rack

increases the possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads

high on the racks raises the center of gravity of the vehicle and creates a less

stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehi-

cle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load

and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use

extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing

the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle

should never exceed 10 mph (16 kph) while towing a load on a level surface.

Vehicle speed should never exceed 5 mph (8 kph) when towing loads in

rough terrain, while cornering, or while ascending or descending a hill.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Procedures

1. Wear protective riding gear. See page 10.

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

handlebars.

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

4. Shift the transmission into gear.

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

6. Release the parking brake.

7. Slowly depress the throttle with your right thumb and begin driving.

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

brakes on level surfaces.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Turning the Vehicle

Your ATV is equipped with a

solid rear axle, which drives

both rear wheels equally at all

times. This means that the

wheel on the outside of the turn

must travel a greater distance

than the inside wheel when

turning and the inside tire must

slip traction slightly.

To turn, steer in the direction of

the turn, leaning your upper

body to the inside of the turn

while supporting your weight

on the outer footrest. This tech-

nique alters the balance of trac-

tion between the rear wheels,

allowing the turn to be made

smoothly. The same leaning

technique should be used for

turning in reverse.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving on Slippery Surfaces

Whenever riding on slippery

surfaces such as wet trails or

loose gravel, or during freez-

ing weather, follow these

precautions:

1. Slow down when enter-

ing slippery areas.

2. Engage AWD before

wheels begin to lose

traction.

3. Maintain a high level of

alertness, reading the

trail and avoiding quick,

sharp turns, which can

cause skids.

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

and shifting your body weight forward.

CAUTION

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

wheels are spinning. Always allow the rear wheels to stop spinning before

engaging AWD, or engage AWD before wheels begin to lose traction.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Uphill

25° Maximum

Whenever traveling uphill, follow these precautions:

1. Drive straight uphill.

2. Avoid steep hills (25° maximum).

3. Keep both feet on the footrests.

4. Shift your weight uphill.

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 seri-

ous 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.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving on a Sidehill (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 dangerous and should be avoided if at all possible. If

you encounter a situation where sidehilling is necessary, follow these

precautions:

1. Slow down.

2. Shift your weight uphill.

3. Keep your feet on the footrests.

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

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if pos-

sible, or dismount on the uphill side immediately!

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Downhill

WARNING

Excessive speed when traveling downhill can cause loss of control and seri-

ous injury or death. Slow down.

Applying the brakes too firmly may cause the rear wheels to lock, which

could result in loss of control and serious injury or death. Apply the brakes

gradually.

When driving downhill, follow these precautions:

1. Shift your weight uphill.

2. Drive straight downhill.

3. Slow down.

4. Squeeze the brake lever gradually.

NOTE: Before operating your ATV, learn how to use the auxiliary brake for

emergency situations (if single-lever brakes become inoperable).

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Turning Around on a Hill (K-Turn)

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

Use the K-turn to turn around.

8 ft. (2.4 m)

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Turning Around on a Hill (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 vehi-

cle is pointing straight uphill.

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

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

slowly allow the vehicle to roll around to your right until it's point-

ing across the hill or slightly downward.

6. Lock the parking brake. Remount the vehicle from the uphill side,

keeping body weight uphill.

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

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

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

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Through Water

Maximum Depth

Your ATV can operate through water with a maximum recommended

depth equal to the bottom of the footrests. 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.

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

until braking action is normal.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving Through Water

After running the vehicle in water, it's critical to have it serviced as out-

lined in the maintenance chart. See page 68. 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 100. Have

the vehicle serviced by your dealer at the first opportunity.

Download from Www.Somanuals.com. All Manuals Search And Download.

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 hid-

den obstacle. Not all obstacles are immediately visible. Travel with caution in

unfamiliar terrain.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Driving in Reverse

Follow these precautions

when operating in reverse:

1. Always check for

obstacles or people

behind the vehicle.

2. Always avoid backing

downhill.

3. Back slowly.

4. Apply the brakes

lightly for stopping.

5. Avoid turning at sharp

angles.

6. Never open the throttle suddenly.

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. Use the

override button with caution as rearward vehicle speed is greatly

increased. Do not operate at wide open throttle.

CAUTION

Excessive throttle operation while in the speed limit mode may cause fuel to

build in the exhaust, resulting in engine popping and/or engine damage.

Operate the throttle just enough to maintain a desired speed.

Download from Www.Somanuals.com. All Manuals Search And Download.

OPERATION

Driving Safely

Parking on an Incline

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

precautions:

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

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

5. Turn the fuel valve off.

Download from Www.Somanuals.com. All Manuals Search And Download.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

may affect compliance with U.S.A. EPA noise control requirements (40

CFR 205) and local noise level requirements.

Operation on Public Lands in the U.S.A.

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

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

eral law requires that this spark arrestor be installed and functional when

the vehicle is operated on public lands.

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

by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Fed-

eral regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

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

exhaust gases exit through the exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are controlled by engine

design, including factory-set fuel delivery and ignition. The engine and

related components must be maintained at Polaris specifications to

achieve optimal performance.

Engine idle speed is the only adjustment Polaris recommends that the

operator perform. Any other adjustments should be performed by an

authorized Polaris dealer.

The compliance label is located on right front portion of the frame or on

the rear independent rear suspension (IRS) tube.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European direc-

tives 97/24/EC and 89/336/EEC.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

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

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

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

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 134.

NOTE: Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have

a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average

riding conditions and an average vehicle speed of approximately 10

miles per hour (16 km/h). Vehicles subjected to severe use must be

inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

weather can indicate contaminants collecting in the oil sump or crank-

case. Change oil immediately if the oil level begins to rise. Monitor the

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

cause or see your dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Perform these operations more often for vehicles subjected to

severe use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

Have an authorized Polaris dealer perform these services.

WARNING

Improperly performing the procedures marked with a Q could result in com-

ponent failure and lead to serious injury or death. Have an authorized Polaris

dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 49.

X Front suspension

X Rear suspension

Tires

X Brake fluid level

X Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

X Engine oil level

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Coolant

(if applicable)

Check level daily, change

coolant every 2 years

Headlamp/tail

lamp

Daily

Check operation; apply

dielectric grease if replacing

X Air filter,

E main element

Weekly

Inspect; replace as needed

Recoil housing

(if applicable)

Drain water as needed,

check often if operating in wet

conditions

X Brake pad wear

10 H

Monthly

100 (160) Inspect periodically

Battery

20 H

25 H

Monthly

200 (320) Check terminals; clean; test

250 (400) Inspect level; change yearly

X Front gearcase oil

(if equipped)

X Transmission oil

25 H

Monthly

250 (400) Inspect level; change yearly

250 (400) Inspect; clean if needed

X Engine breather

E filter (if equipped)

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X General

50 H

3 M

6 M

500 (800) Lubricate all fittings, pivots,

cables, etc.

lubrication

Carburetor float

bowl

500 (800) Drain bowl periodically and

prior to storage

Throttle Cable/

ETC Switch

500 (800) Inspect; adjust; lubricate;

replace if necessary

Choke cable

50 H

6 M

500 (800) Inspect; adjust; lubricate;

replace if necessary

E Carburetor air

500 (800 Inspect duct for proper seal-

ing/air leaks

intake ducts/flange

Drive belt

500 (800) Inspect; adjust; replace as

needed

Cooling system

(if applicable)

1000 (1600) Inspect coolant strength

seasonally; pressure test

system yearly

X Engine oil change 100 H

6 M

1000 (1600) Perform a break-in oil change

at 20 hours

X Oil filter change 100 H

6 M

1000 (1600) Replace with oil change

1000 (1600) Inspect routing, condition

X Oil tank vent hose 100 H

(if equipped)

Valve clearance

100 H

12 M

1000 (1600) Inspect; adjust

Fuel system/filter

1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,

carburetor; replace lines

every two years

X Radiator

(if applicable)

100 H

12 M

1000 (1600) Inspect; clean external

surfaces

X Cooling hoses

1000 (1600) Inspect for leaks

(if applicable)

X Engine mounts

100 H

12 M

1000 (1600) Inspect

Exhaust muffler/

pipe

Spark plug

100 H

12 M

1000 (1600) Inspect; replace as needed

1000 (1600) Inspect

Ignition Timing

X Wiring

1000 (1600) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

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

200 H

300 H

24 M

36 M

2000 (3200) Change every two years

3000 (4800) Clean out

Spark arrestor

Idle speed

Adjust as needed

Toe adjustment

Inspect periodically; adjust

when parts are replaced

Headlight aim

Adjust as needed

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 68. Items not listed in the

chart should be lubricated at the General Lubrication interval.

Item

Lube

Method

Engine Oil

PS-4 PLUS Performance See page 74.

Synthetic 2W-50

Brake Fluid

DOT 4 Only

See page 86.

See page 78.

Transmission Oil

Polaris AGL Synthetic

Gearcase Lube

Front Demand Drive

Unit (Front Gearcase)

Premium Demand Drive

Hub Fluid

See page 81.

Front Prop Shaft Yoke

Grease fittings (3 pumps maxi-

Control Arm (front and

rear)

Polaris Premium U-Joint mum) every 500 miles (800 km),

Lube

before long periods of storage, or

after pressure washing or sub-

merging.

Bearing Carrier

Transmission (upper

pivot point)

Transmission Upper

Pivot Point

Front Prop Shaft Yoke

Bearing

Carrier

Control Arms

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to

be changed more frequently if Polaris oil is not used. Always use 2W-50

oil. Follow the manufacturer's recommendations for ambient tempera-

ture operation.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use the recommended oil. Never substitute or mix oil

brands.

Oil Specifications

Lubricant

Capacity

Drain Plug Torque

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

2 qts. (1.9 l)

14 ft. lbs. (19 Nm)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Engine Oil

Oil Level

The oil dipstick is located behind the

left front tire.

1. Position the vehicle on a level

surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Clean away all dirt and debris on

the oil tank or in the wheel well area.

5. Start the engine. Allow it

to idle for 30 seconds.

Stop the engine.

Dipstick

6. Remove the dipstick.

Wipe it dry with a clean

cloth.

7. Reinstall the dipstick

completely.

8. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

Safe Range

Safe

Add Oil

9. Reinstall the dipstick.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Oil and Filter Change

CAUTION

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

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

Maintenance Chart beginning on page 68. To change the oil properly,

always drain the oil tank and change the oil filter.

NOTE: If oil contamination (water, mud, metal shavings) is suspected in the

engine sump, the sump should also be drained. Draining the engine

sump will require additional oil not contained in the oil change kit. The

total oil capacity of the engine sump and oil tank combined is 2.25 qts.

(2.1 liters).

1. Position the vehicle on a level

surface.

2. Place the transmission in neutral.

3. Lock the parking brake.

4. Start the engine. Allow it to idle for

two to three minutes. Stop the

engine.

5. Clean the area around the oil tank

drain plug.

6. Place a drain pan under the oil tank.

7. Remove the drain plug. Use a 14

mm wrench.

8. Drain the oil.

9. Reinstall the oil tank drain plug.

NOTE: The sealing surfaces on the drain plug and oil tank should be clean

and free of burrs, nicks or scratches.

10. Torque to specification. See page 74.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Oil and Filter Change

11. Place towels under the oil filter.

Using an oil filter wrench, turn

the filter counterclockwise to

remove it.

12. Clean the filter sealing area on

the engine.

13. Lubricate the filter o-ring.

Check to make sure the o-ring

is in good condition.

14. Install the new oil filter. After the filter contacts the engine surface,

turn it 1/2 turn by hand.

15. Remove the dipstick.

16. Add the recommended oil. See page 74.

17. Reinstall the dipstick.

18. Start the engine. Allow it to idle for two minutes.

19. Stop the engine.

20. Check for oil leaks.

21. Remove the dipstick and check the oil level. Add oil as needed.

Maintain the oil level in the safe range. Do not overfill.

Safe Range

Safe

Add Oil

22. Reinstall the dipstick.

23. Discard used oil and filter properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transmission Oil

Always check and change

the transmission oil at the

intervals outlined in the

Periodic Maintenance

Chart beginning on page

68. Maintain the oil level

at the bottom of the fill

plug hole. See page 121

for the part numbers of

Polaris products.

Drain Plug

The fill plug is located on

the left side of the ATV,

under the rear fender,

behind the wheel. The

drain plug is located

Fill Plug

behind the wheel well.

Transmission Oil Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Drain Plug

Torque

Transmission Premium AGL Synthetic

Gearcase Lubricant

20.3 oz.

(600 ml)

15 ft. lbs.

(20 Nm)

15 ft. lbs.

(20 Nm)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transmission Oil

Oil Check

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Remove the fill plug.

Use a 15 mm wrench.

5. Check the oil level.

6. Add oil as needed. Do

not overfill.

7. Reinstall the fill plug.

Torque to specification.

See page 78 for recom-

mendations.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transmission Oil

Oil Change

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Remove the fill plug.

Use a 15 mm wrench.

5. Place a drain pan under

the gearcase.

6. Remove the drain plug.

Use a 15 mm wrench.

7. Allow the oil to drain

completely.

8. Clean and reinstall the drain

plug. Torque to

specification. See page 78

for recommendations.

9. Add the recommended oil.

10. Reinstall the fill plug.

Torque to specification. See

page 78 for recommenda-

tions.

11. Check for leaks.

12. Dispose of used oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the

demand drive fluid at the inter-

vals outlined in the Periodic

Maintenance Chart beginning

on page 68. We recommend the

use of Polaris Premium

Fill

Plug

Demand Drive Hub Fluid. Use

of other oils may result in

Fill

Level

improper operation of compo-

nents. See page 121 for the part

numbers of Polaris products.

Drain Plug

Maintain the fluid level at the

bottom of the fill hole threads.

The fill plug is located on the

right side of the gearcase. The

drain plug is located on the bot-

tom right side of the gearcase.

Demand Drive Fluid Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Demand Drive Premium Demand Drive

Unit Hub Fluid

5 oz.

(148 ml)

8-10 ft. lbs.

(11-13 Nm)

8-10 ft. lbs.

(11-13 Nm)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Check

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Remove the fill plug. Use

an 8 mm Allen wrench.

5. Check the oil level.

6. Add the recommended oil

as needed to bring the level

to the bottom of the fill

hole threads.

7. Reinstall the fill plug.

Torque to specification.

See page 81.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Remove the fill plug. Use an 8

mm Allen wrench.

5. Place a drain pan under the

gearcase.

6. Remove the drain plug. Use an

8mm Allen wrench.

7. Allow the oil to drain completely.

8. Clean and reinstall the drain

plug. Torque to

specification. See page 81.

9. Add the recommended fluid.

10. Reinstall the fill plug.

Torque to specification.

11. Check for leaks.

12. Dispose of used oil properly.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

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

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

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

As coolant operating temperature increases, the expanding (heated)

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

the recovery bottle. As engine coolant temperature decreases the con-

tracting (cooled) coolant is drawn back up from the bottle, past the pres-

sure cap, and into the radiator.

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

purging itself of trapped air. Check the coolant level and maintain as

recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-

ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/

coolant and distilled water. Polaris Premium 60/40 is already premixed

and ready to use. Do not dilute with water. See page 121 for the part

numbers of Polaris products.

NOTE: Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located

under the front storage box cover

near the radiator cap. Maintain

the coolant level between the

minimum and maximum marks

on the bottle (when the fluid is

cool).

1. Position the vehicle on a

level surface.

2. Open the front storage box

cover.

3. View the coolant level.

4. Add coolant as needed.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cooling System

Radiator Coolant

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

Polaris recommends that you drain the system completely every two

years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for

maintenance or repair. If the recovery bottle has run dry, check the level

in the radiator. Add coolant as needed.

WARNING

Escaping steam can cause severe burns. Never remove the pressure cap

while the engine is warm or hot. Always allow the engine to cool before

removing the pressure cap.

1. Open the front storage box

cover.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radia-

tor filler neck.

4. Reinstall the pressure cap.

5. Secure the box cover.

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.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride.

Always maintain brake fluid at the recommended level. Do not overfill.

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which

could result in serious injury or death. Maintain brake fluid at the recom-

mended level. Do not overfill.

If the fluid level is low add DOT 4 brake fluid only. See page 121 for the

part numbers of Polaris products.

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.

Under normal operation, the diaphragm extends into the reservoir as

fluid level drops. If the fluid level is low and the diaphragm is not

extended, a leak is likely and the diaphragm should be replaced. To

ensure proper diaphragm operation, always fill the reservoir as needed

whenever the cover is loosened or removed. Do not overfill.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brake Fluid

Hand Brake

Master Cylinder

The master cylinder is located

on the left handlebar. Main-

tain the fluid level 1/4" (6.3

mm) below the top edge of the

master cylinder. Do not over-

fill.

Indicator

Window

1. Position the vehicle on a

level surface. Make sure

the handlebars are

straight.

Full

2. View the fluid level

through the indicator win-

dow (eye) on the top of

the master cylinder.

NOTE: The eye will appear

dark when the fluid

level is full. When fluid

is low, the eye will be

clear.

Low

3. Add the recommended

fluid as needed. Do not

overfill.

Maximum

Minimum

Foot Brake

The brake fluid reservoir is

located in the front storage

box. Maintain the fluid level

between the minimum and

maximum marks. Do not

overfill.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Brakes

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

the single brake lever toward the handlebar. The auxiliary foot brake is

also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

The following checks are recommended to keep the brake system in

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

under normal operation.

1. Always keep brake fluid at an

adequate level. See page 86.

2. Check the brake system for

fluid leaks.

3. Check the brakes for excessive

travel or spongy feel.

4. Check the friction pads for

wear, damage and looseness.

Replace the pads when the fric-

tion material is worn to .03" (.8

mm).

5. Check the security and surface

condition of the disc.

.03" (.8 mm)

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and adjust-

ment. Do not attempt to adjust tie rod alignment. All tie rod adjustments

should be performed by an authorized Polaris dealer.

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

The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

Stand

String

3. Tie a length of string

between two stands as

shown in the illustration.

Position the stands so

that the string is flush

with the side of the rear

tire.

NOTE: If available, you may

use a long straight-

edge instead of string.

4. Measure the distance

from the string to the

rim at the front (1) and

rear (2) of the front rim.

The rear measurement should be 1/16"-1/8" (2-3 mm) more than the

front measurement on each side of the vehicle to obtain the recom-

mended 1/8" to 1/4" (3-6 mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

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

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Steering Assembly

The steering assembly of the ATV should be checked periodically for

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

dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

2. Grasp the top of the side panel and pull it outward to remove it.

Footwell Removal

1. Remove the two screws on the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the plastic rivets

securing the footwell to the fenders.

3. Remove the footwell.

Screws

Rivets

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Tires

Refer to the specifications section beginning on page 126 for recom-

mended tire type, size and pressure.

WARNING

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

tires or improperly installed tires will affect vehicle handling and could cause

an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in

the owner's manual.

Always use original equipment size and type when replacing tires.

Make sure the wheels are installed properly.

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

Tire Tread Depth

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

1/8" (3 mm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com-

ponent operations. All service must be performed by your authorized

Polaris dealer.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Tires

Wheel Removal

1. Position the vehicle on a level

surface.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

5. Place a suitable stand under the

footrest frame to raise the wheel

slightly off the ground.

6. Remove the wheel nuts.

7. Remove the wheel.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Tires

Wheel Installation

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle han-

dling, 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 wheel on the wheel

hub with the valve stem

toward the outside and the

rotation arrows on the tire

pointing toward forward

rotation.

2. Install the wheel nuts finger

tight.

3. Lower the vehicle to the ground.

4. Torque the wheel nuts to

specification.

Wheel Nut Torque Specifications

27 ft. lbs.

(37 Nm)

90 ft. lbs.

(122 Nm)

CAST ALUMINUM

STEEL

Check the wheel nut torques occasionally and when they've been loos-

ened for service.

Nut Type

Nut Torque

Lug Nut

90 ft. lbs. (122 Nm)

27 ft. lbs. (37 Nm)

2-Piece Flange Nut

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Air Filter

1. Position the vehicle on a level

surface. Place the transmission

in gear.

2. Lock the parking brake.

3. Remove the seat.

4. Release the air box cover clips,

and remove the air box cover.

Pre-Filter

Main Filter

5. Loosen the clamp and remove

the filter.

6. Remove the fabric type pre-fil-

ter from the main filter. Wash

the pre-filter in soapy water,

then rinse and let dry.

7. Reinstall the pre-filter over the

main filter.

NOTE: Install a new main filter if

needed.

8. Reinstall the filter into the air

box and tighten the clamp. Do

not over-tighten the clamp, as

filter damage could occur.

Breather

Filter

9. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. Remove the left side panel. See page 90.

2. Remove the hose clamps from the filter and pull the filter out of the

hoses. Inspect the filter for debris. Blow gently through the filter in

the direction of the arrow to check for clogging. Replace a damaged

or clogged filter.

3. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed. Reinstall the filter and hose clamps.

NOTE: The filter is effective with the arrow pointing in either direction.

CAUTION

Operation of your vehicle without a breather filter can cause engine damage.

Always reinstall the breather filter after removing it for service.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use

the following procedure to make the adjustment.

25 ft.

(7.6 m)

2" (5 cm)

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

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

2. Place the transmission in neutral.

3. Lock the parking brake.

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

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

NOTE: Include rider weight on the seat when measuring.

5. Start the engine.Turn the headlight switch to high beam.

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

headlight beam should be two inches (5 cm) below the mark on the

wall.

7. Loosen the phillips screw at the rear of the headlamp.

8. Adjust the beam.

9. Tighten the screw.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Lights

When servicing a halogen lamp, don't touch the lamp with bare fingers.

Oil from your skin leaves a residue, causing a hot spot that will shorten

the life of the lamp.

WARNING

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

taillight lenses become dirty during normal operation. Wash the headlights

frequently to maintain lighting quality.

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

servicing.

Headlamp Replacement

1. Turn the back of the headlight

harness 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.

Harness

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

1. From the rear of the brake-

light, remove the two

screws holding the lens

cover in place. Remove the

lens cover.

Lamp

Cover

2. Remove the lamp and

replace it with a new lamp.

3. Test the light for proper

operation.

4. Reinstall the lens cover.

Screw

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Recoil Housing

Always drain the recoil housing after operating the vehicle in wet condi-

tions. Drain the housing before storing the vehicle. Make sure the hous-

ing is completely dry before reinstalling the drain plug.

1. Place the transmission in gear.

2. Lock the parking brake.

3. Stop the engine.

4. Remove the drain screw on the

bottom of the recoil housing.

5. Reinstall the drain screw.

NOTE: Do not open the crankcase drain

unless the engine has ingested

water. On 4-cycle engines, some

engine oil will be lost if the crank-

case drain is opened.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

CAUTION

Using non-recommended spark plugs can result in serious engine damage.

Always use Polaris-recommended spark plugs.

Refer to the specifications section beginning on page 126 for the recom-

mended spark plug type and gap for your vehicle. Torque spark plugs to

specification.

Plug Condition

Torque Specification

New Spark Plug

9-11 ft. lbs. (12-15 Nm)

17-20 ft. lbs. (23-27 Nm)

Previously Installed Spark Plug

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark

plug firing end condition after the engine has been warmed up and the

vehicle has been driven at higher speeds. Immediately check the spark

plug for correct color. See page 99.

WARNING

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

gloves when removing a spark plug for inspection.

1. Remove the seat. Remove the right side panel.

2. Remove the fuel tank cover.

3. Rotate the spark plug cap 1/4 turn and pull it off the spark plug. If

necessary, use a needle-nose pliers to assist.

4. Using a 5/8" socket with a long extension, access the spark plug

through the fuel tank cover opening. Rotate the spark plug

counterclockwise to remove it.

5. Reverse the procedure for spark plug installation. Torque to

specification.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Spark Plug

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

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

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

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

carburetion adjustments.

Wet Fouled Spark Plug

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

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

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

of non-recommended oil, improper use of the choke, or incorrect throt-

tle body/carburetor adjustments.

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the

machine is not thoroughly inspected. Take the vehicle to your dealer before

starting the engine.

If it's impossible to take your

ATV to a dealer before starting

it, follow the steps outlined

below.

1. Move the vehicle out of the

water.

2. Turn the fuel valve off.

3. Check the air box. If water is

present, dry the air box and replace

the filter with a new filter.

4. Remove the spark plug.

5. Loosen the carburetor drain screw

and drain the carburetor.

6. Turn the engine over several times

using the electric start.

7. Dry the spark plug. Reinstall the

plug or install a new plug.

Drain

Screw

8. Tighten the carburetor drain screw.

9. Turn the fuel valve on.

10. Attempt to start the engine. If necessary, repeat the drying proce-

dure.

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

you succeed in starting it or not.

12. If water has been ingested into the PVT, follow the procedure on

page 103 for drying out the PVT.

100

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor

could result in serious injury or death.

The exhaust system can get extremely hot. Do not perform service on the

spark arrestor while the system is hot. Allow components to cool sufficiently

before proceeding.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. Do not stand behind or in front of the vehicle while purg-

ing. Never run the engine in an enclosed area. Exhaust contains poisonous

carbon monoxide gas. Never go under the vehicle while it's inclined.

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe/muffler.

1. Position the vehicle on a

level surface.

2. Place the transmission in

Exhaust

Outlet

neutral.

3. Lock the parking brake.

4. Remove the arrestor

clean-out plug from the

bottom of the muffler.

Clean-Out Plug

5. Start the engine.

6. Quickly squeeze and release the throttle lever several times to purge

carbon from the system.

7. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

8. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 6.

9. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

10. Place the transmission in neutral. Lock the parking brake. Repeat

steps 6 to 8 until no more particles are expelled.

11. Stop the engine. Allow the arrestor to cool.

12. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

101

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

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 fol-

lowing 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.

102

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

PVT System

PVT Drying

There may be some instances

when water is accidently

ingested into the PVT system.

Use the following instructions to

dry it out before operating.

1. Move the vehicle out of the

water.

2. Remove the PVT drain plug. Use

a 17 mm wrench, a flat screw-

driver, or the spark plug wrench.

3. Allow the water to drain com-

pletely. Reinstall the drain plug.

4. Start the engine. Place the trans-

mission in neutral.

5. Apply varying throttle for 10-15

seconds to expel the moisture

and air-dry the belt and clutches.

PVT Drain

Plug

NOTE: Do not hold the throttle wide

open for more than 10 seconds.

6. Allow the engine RPM to settle

to idle speed, then shift the trans-

mission into forward gear.

7. Test for belt slippage. If the belt

slips, repeat the process.

8. Take the vehicle to your dealer

for service as soon as possible.

103

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Your ATV may have either a sealed battery, which requires little mainte-

nance, or a conventional battery. A sealed battery can be identified by its

flat covers on the top of the battery. A conventional battery has six filler

caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove corrosion with a stiff wire brush. Wash

with a solution of one tablespoon baking soda and one cup water. Rinse

well with tap water and dry off with clean shop towels. Coat the termi-

nals with dielectric grease or petroleum jelly. Be careful not to allow

cleaning solution or tap water into a conventional battery.

Conventional Battery

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.

away. Ventilate when charging or using in an enclosed space. Always shield

eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

104

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explo-

sion 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. Place the transmission in

gear.

2. Lock the parking brake.

3. Remove the splash shield

behind the right front tire.

4. Remove the left side panel

to access the battery hold-

down bracket. Remove the

screw at the bottom rear of

the bracket and move the

bracket aside.

5. Remove the battery cover.

6. On conventional batteries,

remove the battery vent

tube.

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

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

9. Lift and remove the battery through the right wheel well. If using a

conventional battery, be careful not to tip the battery sideways,

which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon

baking soda and one cup water to prevent damage to the vehicle.

105

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 108 before installing

the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed.

Route the tube away from the frame and vehicle body to prevent con-

tact with electrolyte.

WARNING

Battery gases could accumulate in an improperly installed vent tube and

cause an explosion, resulting in serious injury or death. Always ensure that

the vent tube is free of obstructions and is securely installed as

recommended.

4. Coat the terminals with dielectric grease or petroleum jelly.

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

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

7. Install the battery cover and hold-down bracket.

8. Verify that cables are properly routed.

NOTE: Cables should be safely tucked away at the front and rear of the bat-

tery.

9. Reinstall the left side panel and the right splash guard.

106

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

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 Tender

charger or by charging about once a month to make up for normal self-

discharge. Battery Tender can be left connected during the storage

period, and will automatically charge the battery if the voltage drops

below a pre-determined point. See page 121 for the part numbers of

Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery

Lower

Mark

Upper

Mark

will deteriorate rapidly. Check

the battery fluid level often.

Maintain the fluid level

between the upper and lower

level marks.

Add only distilled water. Tap

water contains minerals that are

harmful to a battery.

107

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 105.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific grav-

ity to 1.270 or greater.

3. Reinstall the battery. See page 106. Make sure the positive terminal

is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa-

tion of a sealed battery. Read all instructions before proceeding with the

installation of this battery.

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

and fully charged at the factory or dealership. Never pry the sealing strip

off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to

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

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

DC voltage.

WARNING

An overheated battery may explode, causing severe injury or death. Always

watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

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 battery voltage is 12.8 or greater.

NOTE: For convenience, a charging harness has been routed from the battery

to the area near the radiator filler cap. Open the front storage box

cover to access the harness.

108

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

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. Always verify battery con-

dition before and 1-2 hours after the end of charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

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

109

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance

but it can also extend the life of various components.

CAUTION

High water pressure may damage components. Polaris recommends wash-

ing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage

plastic surfaces. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden

hose and a pail of mild soap and water.

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

and the lower parts last.

2. Rinse with clean water frequently.

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

Washing Tips

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

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

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

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

reused cloths and pads may contain dirt particles that will scratch the

finish.

110

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components and could

remove paint and decals. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator (if equipped)

• Transmission seals

• Brakes

• Cab and body panels

• Labels and decals

• Coolant (if equipped) (test strength/fill)

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

for free replacement.

Grease all zerk fittings immediately after washing. Allow the engine to

run for a while to evaporate any water that may have entered the engine

or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture

polish for polishing the finish on your Polaris vehicle. Follow the

instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

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

reused cloths and pads may contain dirt particles that will scratch the

finish.

111

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre-

serve wheel life and ensure a "like new" appearance for many years.

NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas)

are more susceptible to corrosion if not properly cleaned. Clean

chrome wheels more often if they're exposed to salt or other corrosive

elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

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

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

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

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

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

lined above.

112

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Storage Tips

CAUTION

Starting the engine during the storage period will disturb the protective film

created by fogging and damage could occur. Never start the engine during

the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See

page 110.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

Follow the instructions on the container for the recommended

amount.

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

removes carbon deposits from pistons, rings, valves and exhaust sys-

tems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

disperse through the fuel in the tank and carburetor.

4. Turn the fuel valve off.

5. Drain the carburetor bowl.

Oil and Filter

Change the oil and filter. See page 76.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Clean or replace the breather filter. See page 94.

4. Drain the sediment tube.

Recoil Housing

1. Drain the recoil housing. See page 97.

113

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

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

Maintenance Chart beginning on page 68.

• Demand drive unit (front gearcase)

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean. See page 113.

2. Support the front end of the machine so the engine is level or tilted

slightly rearward.

3. Remove the spark plug. Rotate the piston to BDC and pour two

ounces (59 ml) of engine oil into the cylinder.

4. Reinstall the spark plug. Torque to specification.

5. Apply dielectric grease to the inside of the spark plug cap. Reinstall

the cap.

6. Turn the engine over several times using the recoil starter. Oil will

be forced in and around the piston rings and ring lands, coating the

cylinder with a protective film of fresh oil.

7. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and carburetor should be completely drained of gasoline.

114

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended

in the Periodic Maintenance Chart beginning on page 68.

Battery Storage

See pages 107-108 for storage and charging procedures.

Storage Area/Covers

Set the tire pressure and safely support the ATV with the tires slightly

off the ground. Be sure the storage area is well ventilated. Cover the

vehicle with a genuine Polaris cover.

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

tilation to prevent condensation, and may promote corrosion and oxi-

dation.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso-

ries. Accessory outlets are available for all models. Polaris also has a

wide range of additional accessories available for your ATV. Always

install accessories that are approved for ATV use. Please see your

Polaris dealer.

115

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE

Transporting the Vehicle

Follow these procedures when transporting the vehicle.

1. Stop the engine.

2. Place the transmission in gear.

3. Lock the parking brake.

4. Turn the fuel valve off.

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

6. Remove the key to prevent loss during transporting.

7. 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.

116

Download from Www.Somanuals.com. All Manuals Search And Download.

ADJUSTMENTS

Camber and Caster

The camber and caster are non-adjustable.

Spring Adjustments

The front and rear shock absorber springs are adjustable. Rotate the

adjuster either clockwise or counterclockwise to increase or decrease

spring tension. Always adjust both sides equally.

NOTE: Accessory springs are available through your Polaris dealer.

Rear

Adjuster

Front

Adjuster

117

Download from Www.Somanuals.com. All Manuals Search And Download.

ADJUSTMENTS

Handlebars

The handlebars can be adjusted for rider preference.

WARNING

Improper adjustment of the handlebars or incorrect torquing of the adjuster

block tightening bolts can cause limited steering or loosening of the

handlebars, resulting in loss of control and possible serious personal injury or

death. Follow the adjustment procedures exactly, or see your Polaris dealer

for service.

1. Loosen the four handlebar bolts.

2. Adjust the handlebar to the

desired height.

NOTE: Be sure the handlebars do not

contact the gas tank or any

other part of the machine

when turned fully to the left or

right.

3. Torque the front two bolts to

10-12 ft. lbs. (14-17 Nm), then

torque the rear two bolts. A gap

Handlebar

of up to 1/8" (3 mm) will

Bolts

remain at the rear bolts.

118

Download from Www.Somanuals.com. All Manuals Search And Download.

ADJUSTMENTS

Carburetor

Your Polaris ATV is calibrated at the factory for optimal performance at

altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of

+40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the

engine air/fuel mixture becomes overly rich and the engine loses

approximately 3% of its power for each 1000-foot (304.8 m) increase in

elevation. Although this power cannot be regained, adjustments to the

carburetor and drive system can be made to allow more efficient opera-

tion. Optional jets, available from your Polaris dealer, are required for

operation above 6,000 feet and temperatures below +40 degrees F. (4

degrees C.)

NOTE: Continuous operation of the engine without proper jetting when

required can cause poor performance, overheating or PVT or engine

damage. See your Polaris dealer for more information about jetting the

ATV for conditions in your area.

Carburetor/Engine Idle RPM Adjustment

If the engine idle speed is not satisfactory, and all other conditions are

favorable, the carburetor can be adjusted.

1. Place the transmission in

gear.

2. Lock the parking brake.

3. Start the engine and allow it to

warm up for approximately

five minutes.

4. Turn the screw in (clockwise)

to raise RPM. Turn the screw

out (counterclockwise) to

lower RPM.

Idle

Adjuster

119

Download from Www.Somanuals.com. All Manuals Search And Download.

ADJUSTMENTS

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable

adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far

enough to expose the end of

the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1/16" to 1/8"

(1.5-3 mm) of freeplay is

achieved at the thumb lever.

NOTE: While adjusting freeplay,

be sure to flip the throttle

lever back and forth.

Boot

5. Tighten the lock nut.

6. Squeeze the end of the rub-

ber boot and slide it over the

cable adjuster to its original

position.

Lock Nut

Adjuster

120

Download from Www.Somanuals.com. All Manuals Search And Download.

POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791

2876244

2876245

Fogging Oil (12 oz. Aerosol)

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

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

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lubricant (qt.)

Premium AGL Synthetic Gearcase Lube (gal.)

Pump for Gallon Jug

Premium Demand Drive Hub Fluid (8 oz.)

Premium Demand Drive Hub Fluid (2.5 gal.)

Coolant

2873602

2873603

2870465

2871654

2872277

2871323

2871534

60/40 Coolant (gal./3.8 l)

60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

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

Premium All Season Grease (3 oz. cartridge)

Premium All Season Grease (14 oz. cartridge)

Starter Drive Grease (2 oz.)

2871312

2871322

2871423

2871460

2871515

2871551

2871329

2872073

2872348

Premium U-Joint Lube (3 oz.)

Premium U-Joint Lube (14 oz.)

Dielectric Grease (Nyogel^TM

)

Chain Lube, Aerosol (6.25 oz.)

Chain Lube, Aerosol (16 oz.)

Additives / Miscellaneous

Carbon Clean Plus (12 oz.)

Fuel Stabilizer (16 oz.)

DOT4 Brake Fluid (12 oz.)

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

2871326

2870652

2872189

2871956

2859044

121

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range (if equipped).

tall trailer in high range

Starting out going up a

steep incline

Use low range (if equipped) or turn around using the K-

turn (see page 60).

Driving at low RPM or

Drive at a higher speed or use low range (if equipped)

ground speed (3-7 MPH) more frequently.

Insufficient warm-up at

low ambient tempera-

tures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Towing/pushing at low

RPM/low ground speed

Use low range only (if equipped).

Utility use/plowing

Use low range only (if equipped).

Stuck in mud or snow

Shift the transmission to low range (if equipped). Care-

fully use fast, aggressive throttle application to engage

clutch. WARNING: Excessive throttle may cause loss of

control and vehicle overturn.

Climbing over large

objects from a stopped

position

Belt slippage from water Dry out the PVT. See page 103. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

PVT system

Clutch malfunction

See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer.

Slippage from failure to

warm up belt

Always warm up the belt by operating below 30 mph (48

km/h) for one mile (1.6 km). Operate 5 miles (8 km) or

more when temperature is below freezing.

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 48.

122

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Blown fuse

Replace fuse

Low battery voltage

Loose battery connections

Loose solenoid connections

Recharge the battery to 12.8 VDC

Check all connections and tighten

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 valve or filter

Water is present in fuel

Fuel valve is turned off

Old or non-recommended fuel

Fouled or defective spark plug(s)

No spark to spark plug

Overuse of choke

Inspect and clean or replace

Drain the fuel system and refuel

Turn the fuel valve on

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Inspect, clean and/or replace spark plugs

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Water or fuel in crankcase

Low battery voltage

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Inspect, clean and/or replace spark

plug(s)

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

123

Download from Www.Somanuals.com. All Manuals Search And Download.

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Idle set too low

Set gap to specs or replace plugs

Adjust idle speed

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Recharge battery to 12.8 VDC

Inspect and replace

Low battery voltage

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel 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

Incorrect jetting

See your dealer

Possible Rich Fuel Cause

Solution

Overuse of choke

Fuel is very high octane

Incorrect jetting

Inspect, clean and/or replace spark plugs

Replace with lower octane fuel

See your dealer

124

Download from Www.Somanuals.com. All Manuals Search And Download.

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 is present in fuel

Inspect and replace

Replace with new fuel

Overuse of choke

Inspect, clean and/or replace spark plugs

Fouled or defective spark plug(s)

Inspect, clean and/or replace spark

plug(s)

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean radiator screen and core, clean

engine exterior, see your dealer

Engine Overheating

Possible Cause

Solution

Low radiator coolant level

Debris lodged in screen

Add coolant.

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

Obstructed cooling fan

Clean any debris or mud that may be

interfering with fan movement.

125

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

Sportsman 400 HO 4X4

Maximum Weight Capacity

365 lbs. (166 kg) (includes weight of opera-

tor, cargo and accessories)

Dry Weight

Fuel Capacity

Engine Oil Capacity

Coolant Capacity

598 lbs. (271 kg)

4.5 gal. (17 l)

2 qts. (1.9 l)

2.2 qts. (2 l)

Transmission Oil

20.3 oz. (600 ml)

5 oz. (148 ml)

70 lbs. (32 kg)

100 lbs. (45 kg)

75 lbs. (34 kg) (Rear rack capacity and tongue

weight not to exceed 100 lbs./45 kg)

Demand Drive Fluid

Front Rack Capacity

Rear Rack Capacity

Hitch Tongue Weight Capacity

Hitch Towing Rating

Unbraked Trailer Towing Capacity*

Overall Length

Overall Width

Overall Height

Wheelbase

Ground Clearance

Minimum Turning Radius

Engine Model Number/Type

Lubrication

750 lbs. (340.2 kg)

1786 lbs. (810 kg)

73 in. (185 cm)

44 in. (112 cm)

46 in. (117 cm)

9 in. (23 cm)

69 in. (175 cm) unloaded

EH460PLE020/4-Cycle, Single Cylinder

Dry sump

Engine Cooling

Displacement

Liquid

455 cc

Bore x Stroke

78.5 x 68

Alternator Output

Compression Ratio

Carburetor

250 w

10.1:1

34mm CV Mikuni

42.5

Pilot Jet

Main Jet

157.5

Needle Jet

Jet Needle

P-6M (829)

4IB33

Pilot Air Jet

160

Engine Idle

1350 RPM

Ignition System

Ignition Timing

DC CDI

14° +/- 2° @ 1500 RPM/30° +/- 2° @ 5000

RPM

Spark Plug / Gap

NGK BKR6E / .035 in. (0.9 mm)

* Based on EU Directive 76/432/EC

126

Download from Www.Somanuals.com. All Manuals Search And Download.

SPECIFICATIONS

Sportsman 400 HO 4X4

Driving System Type

Shift Type

Drive Ratio, Front

Drive Ratio, Final

Tires/Pressure

Automatic PVT (Polaris Variable Transmission)

Side Lever (H/N/R)

3.6:1

15.18:1

Front 24x8-12 / 5 psi (34.5 KPa)

Rear 24x11-12 / 5 psi (34.5 KPa)

Front Suspension

Rear Suspension

Shock Adjustment

Brakes, Front and Rear

Brake, Auxiliary

Brake, Parking

Headlight

MacPherson strut with 7" (18 cm) travel

Progressive rate with 8" (20 cm) travel

CAM

Single-Control Hydraulic Disc

Foot-Activated Hydraulic Disc, Rear Wheel

Hydraulic lock, all wheel

2 Dual Beam on Bumper (37.5 watt)

12V 8.26W

Taillights

Brake Light

12V 26.9W

Battery

12V 14AH

DC Plug-In (rear)

Windshield

Accessory

Speedometer/Odometer/

Tripmeter/Hour Meter

Standard

Fuel Gauge

Standard

Jetting Chart

AMBIENT TEMPERATURE

ALTITUDE

Meters (Feet)

Below 40° F

+40°F and above

(+5°C and above)

(Below 5° C)

0-1800 (0-6000)

Above 1800 (6000)

162.5

150

157.5

145

Clutching Chart

Altitude

Roller

Number of Rollers

Driven Clutch

Meters (Feet)

Weight

Spring

0-1500 (0-5000)

1500-3000 (5000-10000)

3000+ (10000+)

19.5 g / 5413447

7043228

17 g / 5412975

16 g / 5412991

127

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

LIMITED WARRANTY

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

ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against

defects in material or workmanship. Polaris also gives a one year limited warranty on

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

charges for repair or replacement of defective parts which are covered by this warranty.

This warranty begins on the date of purchase. This warranty is transferable to another

consumer during the warranty period through a Polaris dealer.

REGISTRATION

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

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR ATV IS REGISTERED WITH POLARIS.

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

free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

128

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any ATV that

has been altered structurally, modified, neglected, improperly maintained, used for rac-

ing, or used for purposes other than for which it was manufactured, or for any damages

which occur during trailer transit or as a result of unauthorized service or the use of

unauthorized parts. In addition, this warranty does not cover physical damage to paint or

finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in

parts, components or the ATV due to fire, explosions or any other cause beyond Polaris'

control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the ATV. The exclusive remedy for breach of this warranty shall

be, at Polaris' exclusive option, repair or replacement of any defective materials, or com-

ponents or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,

WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY

OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. Some

states do not permit the exclusion or limitation of incidental or consequential damages

or implied warranties, so the above limitations or exclusions may not apply to you if

inconsistent with controlling state law.

129

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX

MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

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

repair Polaris ATVs. When requesting warranty service you must present your copy of

the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO

AND FROM THE DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you

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

perform warranty service.

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

any additional assistance they will contact the appropriate person at Polaris.

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

vary from state to state.

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

terms will remain in effect.

Engine Oil

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

ommend the use of Polaris engine oil for your ATV.

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

by warranty.

SPARK ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-

ments of 43 CFR 8340.1(c) for at least 1000 hours when subjected to normal use and

when maintenance and installation are in accordance with Polaris recommendations.

130

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle's warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer's authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer's authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

131

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

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

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

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

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

132

Download from Www.Somanuals.com. All Manuals Search And Download.

WARRANTY

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited

warranty is in addition to the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the

time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in

materials and workmanship that may keep it from meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is deliv-

ered to the original retail purchaser and ends 30 months (2.5 years) after that date, after

5000 km (3100 miles), or after 500 hours of operation, whichever comes first.

This emission-related warranty covers components whose failure would increase an

engine's emissions, including electronic controls, fuel injection, exhaust-gas recircula-

tion, aftertreatment, or any other system utilized in this vehicle to control emissions.

Replacing or repairing other components not covered by this emissions warranty or the

standard warranty is the responsibility of the owner; including the parts, labor and other

costs associated with recommended maintenance.

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or replacement of any defective materials, components or prod-

ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or any engine that has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-888-704-5290.

133

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

Present this section of your manual to your dealer each time your vehicle is serviced.

This will provide you and future owners with an accurate log of maintenance and ser-

vices performed.

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

134

Download from Www.Somanuals.com. All Manuals Search And Download.

MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

135

Download from Www.Somanuals.com. All Manuals Search And Download.

Philips Blu ray Player BDP5510 User Manual
Philips Car Stereo System MCM2000 User Manual
Philips Flat Panel Television 14PT2683 05 User Manual
Philips Microcassette Recorder LFH0662 User Manual
Philips Stereo System FW C557 37 User Manual
Philips Universal Remote SBC RU 538 00 User Manual
Polycom Telephone IP 300 User Manual
ProForm Home Gym PFANBE35250 User Manual
PYLE Audio Car Video System PLVWR940R User Manual
PYLE Audio MP3 Player PDCD940MP User Manual