Polaris ATV 2001 Owner's Manual
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Polaris ATV 2001 Owner's Manual

Polaris ATV 2001 Owner's Manual

Universal
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See also: Owner's Manual for Maintenance and Safety
2001
ATV
Universal Owner's Safety
and Maintenance Manual
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.

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Summary of Contents for Polaris ATV 2001

  • Page 1 2001 Universal Owner’s Safety and Maintenance Manual Read this manual carefully. It contains important safety information. This is an adult vehicle only. Operation is prohibited for those under 16 years of age.
  • Page 2 WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
  • Page 3 FOREWORD Congratulations and thank you from Polaris Industries Inc. for pur- chasing one of our all-terrain vehicles (ATVs). Built with American engineering and manufacturing know-how, it is designed to pro- vide superior riding comfort, enjoyment, and safety. This manual is furnished to ensure that the operator is aware of safe operating procedures.
  • Page 4 • Never operate an ATV without proper instruction. Take a train- ing course. Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or call Po- laris at 1-800-342-3764 to find out about the training courses nearest you.
  • Page 5 Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speed. • Always have the ATV checked by an authorized Polaris dealer if it has been involved in an accident. • Never operate the ATV on hills too steep for the ATV or for your abilities.
  • Page 6 Reduce speed and follow instructions in this manual for carrying cargo or pulling a trailer. Allow greater distance for braking. FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con- sumer Product Safety Commission at 1-800-638-2772, or Polaris at 1-800-342-3764.
  • Page 7 Please be aware that these modifications may create a substantial safety hazard. Polaris hereby informs you that the warranty on your ATV is termi- nated if any such equipment has been added to the ATV or any modifications have been made to the ATV which increase its speed or power.
  • Page 8 Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year membership in the Polaris PRO Family---the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have chosen the finest recreational vehicle available, people who share an interest in Polaris and its products.
  • Page 9 To order PRO merchandise, complete the order form you receive with your membership packet, take the form to your Polaris dealer and pay for the merchandise. The merchandise will be shipped di- rectly to your home from the PRO merchandise fulfillment center.

  • Page 11: Table Of Contents

    CONTENTS UNDERSTANDING WARNINGS ......SAFETY WARNING AND OPERATION DECALS ... 3-11 DAILY PRE-RIDE INSPECTION .

  • Page 12: Understanding Warnings

    You should review this information on a regular basis. In the event you purchased a used Polaris ATV from a party other than a Polaris dealer, you can obtain this safety training at no charge from any authorized Polaris dealer.
  • Page 13 UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal inju- ry, or loss of life. Read all WARNINGS in this manual carefully. Follow their instructions to remain safe. The following precautionary signal words are used throughout this manual to convey the following messages: This is the safety alert symbol.

  • Page 14: Safety Warning And Operation Decals

    Read and follow the instructions on each decal carefully. In the event any decal becomes illegible or comes off, contact your Polaris dealer for a replacement. Any safety decal needing re- placement will be provided by Polaris at no charge. The part num- ber is printed on the decal.
  • Page 15 SAFETY WARNING AND OPERATION DECALS WARNING IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT. 7079083 E1997...
  • Page 16 SAFETY WARNING AND OPERATION DECALS...
  • Page 17 SAFETY WARNING AND OPERATION DECALS UNDER 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. 7078253 WARNING 25° F Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.
  • Page 18 SAFETY WARNING AND OPERATION DECALS...
  • Page 19 SAFETY WARNING AND OPERATION DECALS WARNING (on rear of seat) WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT ___ REAR ___ MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS ____ LBS.
  • Page 20 SAFETY WARNING AND OPERATION DECALS ATTENTION DOPERATION OF THIS VEHICLE WITHOUT DLiutilisation de ce véhicule sous liélément THE FILTER ELEMENT WILL SEVERELY filtre endommage sévèrement le moteur. DAMAGE THE ENGINE. DNettoyer souvent le filtre à air, surtout dans DCLEAN AIR FILTER OFTEN, MORE FRE- des situations poussiereuses.
  • Page 21 SAFETY WARNING AND OPERATION DECALS 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. Maximum Front Rack Load 90 lbs. 7079102 WARNING DO NOT TOW FROM RACK OR BUMPER. vehicle damage or tipover may result causing severe injury or death.
  • Page 22 Specific carburetor jetting and adjustments are required depending on temperature and altitude. See your Owner’s Manual. Factory setting: 40° to 80° F. at 0-3000 feet. (+5° to 26° C. at 0-900 meters). 7073761 MANUFACTURED OVERRIDE BY: POLARIS IND OVERRIDE SWITCH SWITCH DATE: Reverse Speed is Reverse override limited.

  • Page 23: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper work- ing order each time you ride.

  • Page 24: Operation Warnings

    ATVs are recommended, he or she may not have the skills, abilities, or judgment needed to operate the ATV safely and may be involved in a serious acci- dent. HOW TO AVOID THE HAZARD No one under 16 should operate a Polaris ATV.
  • Page 25 OPERATION WARNINGS WARNING POTENTIAL HAZARD Carrying a passenger on this ATV. WHAT CAN HAPPEN Greatly reduces your ability to balance and control this ATV. Could cause an accident, resulting in harm to you and/or your passenger. HOW TO AVOID THE HAZARD Never carry a passenger.
  • Page 26 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on paved surfaces, including side- walks, paths, parking lots, and driveways. WHAT CAN HAPPEN The ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out of control. HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement whenever pos- sible.
  • Page 27 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or high- ways. WHAT CAN HAPPEN You can collide with another vehicle. HOW TO AVOID THE HAZARD Never operate this ATV on any public street, road or highway, even a dirt or gravel one. In many states it is illegal to operate ATVs on public streets, roads and highways.
  • Page 28 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.
  • Page 29 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Could seriously affect your judgment. Could cause you to react more slowly. Could affect your balance and perception. Could result in an accident. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV.
  • Page 30 OPERATION WARNINGS WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Increases the chance of an accident, including an over- turn. HOW TO AVOID THE HAZARD Never attempt stunts, such as wheelies or jumps. Don’t try to show off.
  • Page 31 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Increases the possibility of an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating condition.
  • Page 32 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating this ATV on un- familiar terrain. WHAT CAN HAPPEN You can come upon hidden rocks, bumps, or holes, with- out enough time to react. Could result in the ATV overturning or going out of con- trol.
  • Page 33 OPERATION WARNINGS WARNING POTENTIAL HAZARD Failure to use extra care when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Could cause loss of traction or vehicle control, which could result in an accident, including an overturn. HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you have learned and practiced the skills necessary to control the ATV on such terrain.
  • Page 34 OPERATION WARNINGS WARNING POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN ATV could go out of control, causing a collision or over- turn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as de- scribed in the Owner’s Manual. See page 76 . Practice turning at low speeds before attempting to turn at faster speeds.
  • Page 35 OPERATION WARNINGS WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as de- scribed in the Owner’s Manual. See pages 79 through 82. Always check the terrain carefully before you start up any hill.
  • Page 36 OPERATION WARNINGS WARNING POTENTIAL HAZARD Going down a hill improperly. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for going down hills as described in the Owner’s Manual. See page 81. NOTE: A special technique is required when braking as you go downhill.
  • Page 37 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly crossing hills or turning on hills. WHAT CAN HAPPEN Could cause loss of control or cause ATV to overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Manual on level ground.
  • Page 38 OPERATION WARNINGS WARNING POTENTIAL HAZARD Stalling, rolling back- wards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN Could result in ATV overturning. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If you lose all forward speed: Keep weight uphill.
  • Page 39 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 40 OPERATION WARNINGS WARNING POTENTIAL HAZARD Operating this 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. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast flowing wa- ter.
  • Page 41 Never modify this ATV through improper installation or use of accessories. All parts and accessories added to this ve- hicle should be genuine Polaris Industries Inc. or equiva- lent components designed for use on this ATV; and should be installed and used according to instructions. If you...
  • Page 42 OPERATION WARNINGS WARNING POTENTIAL HAZARD Overloading this ATV or carrying or towing cargo im- properly. WHAT CAN HAPPEN Could cause changes in vehicle handling which could lead to an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely at- tached.
  • Page 43 OPERATION WARNINGS WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Could cause loss of control or a collision. Could cause the ATV to overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Use extreme caution when riding over large obstacles, such as large rocks or fallen trees.
  • Page 44 OPERATION WARNINGS WARNING After a rollover or an accident, have a qualified service dealer check the complete machine including, but not limited to, brakes, throttle and steering for possible damage. WARNING Safe operation of this rider active vehicle requires good judgement and physical skills.

  • Page 45: Vehicle Identification Numbers

    Remove the spare key and store in a safe place. Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key. The vehicle frame and engine serial numbers are important for model identification when registering your vehicle, obtaining in- surance or whenever replacement parts are required.

  • Page 46: Control And Parts Functions

    CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a reverse speed lim- iter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle is open as loss of control may result, causing severe personal injury or death.
  • Page 47 CONTROL AND PARTS FUNCTIONS Backing your ATV can be dangerous! You could hit an obstacle or person behind you; or the ve- hicle could tip over rearward on a steep incline causing se- vere injury or death. Important Safeguards D Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless addi- tional power is required for vehicle movement.
  • Page 48 CONTROL AND PARTS FUNCTIONS Indicator Lights Each Polaris ATV has indicator lights. The configuration of these lights differs with individual models and not every model is equipped with all the lights. The information in your Owner’s Manual Supplement and in the following box will help you identify the lights on your machine and their function.
  • Page 49 Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilome- ters as well as hours of operation.
  • Page 50 CONTROL AND PARTS FUNCTIONS When the programmed hours are reached, SEr hr will light; when the programmed distance is reached, SErdIS will light. Each time the vehicle is started, the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next service interval.
  • Page 51 CONTROL AND PARTS FUNCTIONS Setting Service Hours (cont.) 6. Repeat step 4 and 5 to program the digits for the service interval selected. (i.e. for service interval of 50 hours set the display to show: 00050 H) 7. To save the changes press and hold the button when any one of the digits is flashing.
  • Page 52 CONTROL AND PARTS FUNCTIONS TO SET SERVICE DISTANCE Same as setting Service Hours, but toggle to SET dIS. TO CHECK WHEN SERVICE IS DUE BY DISTANCE Same as setting Service Hours, but toggle to SET dIS. TO CLEAR THE SERVICE REMINDER FROM THE DIS- PLAY The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval.

  • Page 53: Throttle Lever

    This vehicle is equipped with a Polaris Electronic Throttle Control (ETC) which is de- signed to reduce the risk of a frozen or stuck throttle. In the event the throttle cable should stick in an open position, the engine will stop and power to the rear wheels will cease when the operator releases the throttle lever.
  • Page 54 CONTROL AND PARTS FUNCTIONS The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Once a bottle of brake fluid is opened, use what is necessary and discard the rest.
  • Page 55 CONTROL AND PARTS FUNCTIONS The front and rear brakes are applied by squeezing the left side brake lever toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes which are activated by one lever only. Always test brake lever travel and reservoir fluid level before riding. When squeezed, the lever should feel firm.
  • Page 56 CONTROL AND PARTS FUNCTIONS Parking Brake Always check to be sure that the parking brake has been dis- engaged before operating the ATV. An accident could result causing severe injury if the parking brake is left on while the ATV is operated. Setting the Parking Brake - A 1.
  • Page 57 CONTROL AND PARTS FUNCTIONS Setting the Parking Brake - B 1. Squeeze the left hand brake lever two or three times and hold it. 2. Push the park brake lock (2) into the notches on the mas- ter cylinder body. Release the brake lever.

  • Page 58: Auxiliary Brake

    Brake Pedal Your Polaris ATV has an auxiliary brake provided as a safety fea- ture. It is located on the inside of the right floor board and is oper- ated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes inoperative.
  • Page 59 CONTROL AND PARTS FUNCTIONS Automatic Transmission Gear Selector Operation Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your ma- chine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directly above and for- ward of the engine recoil starter.
  • Page 60 CONTROL AND PARTS FUNCTIONS Manual Shift Operation The engine can only Gear Shift Pedal be started with the transmission in neu- tral. Turn the key to “on” and ensure the stop switch is in the run position. The neutral indicator light should be on.

  • Page 61: Shifting Gears

    CONTROL AND PARTS FUNCTIONS Gear Shift Pedal The gear shift pedal is above the left floorboard. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence. The pedal automatically returns to the horizontal position when released.
  • Page 62 CONTROL AND PARTS FUNCTIONS Shifting to Reverse With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control. Depress the gear shift pedal one stroke. The reverse indicator light will come on. Slowly release the brake lever and press throttle control lightly.
  • Page 63 CONTROL AND PARTS FUNCTIONS Exclusive Demand 4 Drive System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off”...
  • Page 64 CONTROL AND PARTS FUNCTIONS Engage the Demand 4 Drive switch before getting into condi- tions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on. Disengaging Wheel Hubs When backing up while in Demand 4 Drive and then going forward, one or both hubs may remain engaged.
  • Page 65 Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle. Polaris recommends the use of Polaris Premium 60/40 anti- freeze/coolant or a 50/50 mixture of high quality aluminum com- patible anti-freeze/coolant and distilled water.
  • Page 66 CONTROL AND PARTS FUNCTIONS Engine Cooling System Never remove the pressure cap when the engine is warm or hot. Escaping steam can cause severe burns. The engine must be cool before removing the pressure cap. Radiator Coolant Level Inspection NOTE: This procedure is only required if the cooling system has been drained for...
  • Page 67 Polaris recommends the use of Polaris Premium 60/40 anti-freeze/ coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water.
  • Page 68 CONTROL AND PARTS FUNCTIONS Gasoline is highly flammable and explosive under certain conditions. D Always exercise extreme caution whenever handling gasoline. D Always refuel with the engine stopped and outdoors or in a well ventilated area. D Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
  • Page 69 Always return valve to “on” position after refueling machine. Engine Fuel Safety/Fuel/Filter The Polaris ATV is equipped with a unique in-line fuel filter. This filter should be replaced by your dealer after every 100 hours of operation or annually. Do not attempt to clean the fuel filter.
  • Page 70 CONTROL AND PARTS FUNCTIONS Oil System On models with a two cycle engine, use only Polaris injection oil. Never substitute or mix oil brands. Serious engine dam- age and voiding of warranty can result. To avoid serious engine damage always top off the oil level when refueling.
  • Page 71 Polaris in your machine. Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our prod- ucts and highly recommends their use. The only oils recom- mended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.
  • Page 72 Polaris Premium 4 All Season Synthetic engine oil has been spe- cially formulated for use in Polaris 4-cycle engines. It is a fully syn- thetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection.
  • Page 73 CONTROL AND PARTS FUNCTIONS Oil System The oil tank is located on the left side of the vehicle or on the engine, depending on the model. To check the oil: 1. Set machine on a level surface. 2. Start the engine and let it idle for 20-30 seconds.

  • Page 74: Recoil Starter

    Polaris 4-cycle engines are equipped with automatic decompres- sors. This makes recoil starting possible by allowing compression to “leak” at cranking speeds. The decompressor senses when the engine is spinning fast enough to start and restores compression for starting.
  • Page 75 CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet condi- tions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Using a wrench, remove the screw.

  • Page 76: Starting The Engine

    STARTING THE ENGINE Procedure for Starting a Cold Engine Never run an engine in an enclosed area. Carbon monox- ide exhaust gas is poisonous and can cause severe injury or death. Always start engines outdoors. You must allow your vehicle adequate warm up time before operating or engine damage could result.

  • Page 77: Starting The Engine

    (3). Cold Weather Operation - 4 Cycle Engines Polaris offers the following kits for cold weather operation: Oil Tank Cover, Engine Heater and Oil Tank Heater. These kits re- duce moisture accumulation in the oil tank when the ATV is op- erated in freezing temperatures.

  • Page 78: Vehicle Break In Period

    VEHICLE BREAK-IN PERIOD 2-Cycle Engines The break in period for your new Polaris ATV is defined as the time it takes to use the first tank of gasoline. No single action on your part is as important as a proper break in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine.
  • Page 79 VEHICLE BREAK-IN PERIOD After the break in period the oil injection system provides the nec- essary engine lubrication without the need for pre-mixed fuel. Fill the oil tank when you refuel your ATV. If you don’t se- rious engine damage could result. After the first tank of pre-mixed fuel has been used please verify that the oil level in the oil tank has dropped, indicating that the oil pump is functioning properly.
  • Page 80 VEHICLE BREAK-IN PERIOD 4-Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break in period.

  • Page 81: Riding Gear

    RIDING GEAR Safe Riding Gear Always wear clothing suited to the type of riding you are doing. ATV riding requires special protective clothing which will make you feel more comfortable and reduce chances of injury. 1. Helmet Your helmet is the most impor- tant piece of protective gear for safe riding.

  • Page 82: Carrying Loads

    CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When oper- ating over rough or hilly terrain, reduce speed and cargo to main- tain stable driving conditions.
  • Page 83 CARRYING LOADS Correct loading of this vehicle is necessary to maintain prop- er stability and operating characteristics. Overloading or in- correct positioning of the load affects the vehicle’s turning, stopping distance and stability. Failure to follow loading re- quirements could cause severe injury or death. 2/3 of Load on 1/3 of Load on Rear Rack...
  • Page 84 CARRYING LOADS LOADS MUST BE CARRIED 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. When cargo loads are car- ried high on the racks, the weight of the loads must be reduced to maintain stable operating conditions.

  • Page 85: Daily Pre-Ride Inspection

    DAILY PRE-RIDE INSPECTION You must inspect your ATV each time before riding to ensure it is in proper working order. If proper inspection is not done, severe injury or death could result. Use the following checklist to verify your machine is in proper work- ing order each time you ride.

  • Page 86: Riding

    RIDING 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. 3. Check your surroundings and determine your path of travel. 4.

  • Page 87: Making Turns

    Making Turns Practice making turns at slow speeds. Polaris ATVs are 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.
  • Page 88 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special atten- tion must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas. 2.
  • Page 89 RIDING Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur. Failure to exercise care when operating the ATV on slippery surfaces can be dangerous. Loss of tire traction and vehicle control can result in an acci- dent, including an overturn.
  • Page 90 RIDING Traveling Uphill 25_ Maximum Exercise extreme caution when traveling in hilly terrain. Braking and handling are greatly affected. Loss of vehicle control or overturning of the ATV could occur causing se- vere injury or death. Whenever traveling uphill always travel straight uphill and: 1.
  • Page 91 RIDING Sidehilling Sidehilling your ATV is one of the most dangerous types of riding and should be avoided if possible. In the event you do enter into a situation where sidehilling is necessary, always: 1. Slow down. 2. Lean into the hill transferring your upper body weight toward the hill while keeping your feet on the footrests.

  • Page 92: Traveling Downhill

    RIDING Traveling Downhill Whenever descending a hill, always: 1. Drive directly downhill. 2. Transfer your weight to the rear of the vehicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing. Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs.

  • Page 93: Turning Around On A Hill

    RIDING Turning Around On A Hill 8’ Uphill If the ATV stalls while climbing a hill, never back it down the hill! One maneuver which can be used when it is necessary to turn around while climbing a hill is the K-turn. 1.

  • Page 94: Crossing Streams

    RIDING Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles if possible.
  • Page 95 RIDING If your ATV becomes immersed, take it to your dealer before starting the engine. Major engine damage can result if the machine is not thoroughly inspected. If it is impossible to take it to a dealer before starting, follow the steps outlined below.

  • Page 96: Trail Obstacles

    RIDING Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Not all obstacles are visible.
  • Page 97 6. Never activate override button while throttle is open. Loss of control may result. NOTE: Most Polaris ATVs are equipped with a reverse speed limit- er. The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle.
  • Page 98 RIDING Parking on an Incline...
  • Page 99 RIDING Whenever the Vehicle is Parked 1. Turn the engine off. 2. Place the transmission in gear or in park. 3. Set the parking brake. 4. Avoid parking on an incline. If it is necessary to park on an in- cline, always block the rear wheels on the down hill side as shown above.

  • Page 100: Pvt System

    Low Range Use May Reduce PVT Operating Temperatures The basic operation of the Polaris PVT system is dependent on en- gine speed and vehicle torque requirements. As engine speed in- creases, the force exerted on the movable drive sheave by the fly- weights also increases.

  • Page 101: Pvt Drying

    PVT SYSTEM OPERATION On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed.
  • Page 102 PVT SYSTEM OPERATION When To Use Low Range vs. High Range The following lists provide a guideline for when to use low range rather than high. Low Range: S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain (swamps, mountains, etc.) at low ground speeds High Range:...

  • Page 103: Battery

    BATTERY Battery Whenever removing the battery, disconnect the negative (black) cable first. When reinstalling the battery, connect the negative (black) cable last or an explosive situation could re- sult causing serious injury or death. Battery electrolyte is poisonous. It contains sulfuric acid. Se- rious burns can result from contact with skin, eyes or clothing.

  • Page 104: Battery Removal

    BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and bat- tery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5.
  • Page 105 BATTERY 1. Set the battery in its holder. 2. Install the battery vent tube. It must be free from obstructions and securely installed. If not, battery gases could accumulate and cause an explosion. The tube should be routed away from the frame and body to prevent corrosion.

  • Page 106: Noise Emission Control System Regulation

    D Be especially careful when traveling through tall grass. The potential for fire exists. USFS Approved Spark Arrestor Most Polaris ATVs have mufflers that were tested and approved in accordance with the USFS Forest Service Standard 5100-1A. For specific information on your model, see the Owner’s Manual...

  • Page 107: Maintenance

    MAINTENANCE Spark Arrestor When cleaning the spark arrestor, you must follow the safe- guards listed below to avoid serious injury or death. D Do not perform this operation immediately after the en- gine has been run because the exhaust system be- comes very hot.
  • Page 108 MAINTENANCE 4. If particles are still sus- pected to be in the muffler, back the ma- chine onto an incline so the rear of the ma- chine is one foot high- er than the front. Set the parking brake and block wheels.
  • Page 109 MAINTENANCE Tool Kits To help you perform routine maintenance, a tool kit is provided in the storage compartment under the seat. Items included in the kits are: 2-cycle engines D flat screwdriver D spark plug wrench with Phillips head screwdriver D wrench D tire pressure gauge D spanner wrench for adjusting rear shock spring preload (se-...

  • Page 110: Periodic Maintenance Schedule

    Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for replacement parts. Al- ways use genuine Polaris parts available from your Polaris dealer. Service and adjustments are critical. If you are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.
  • Page 111 Daily Drain deposits whenev- " Tube er visible Headlamp Inspec- Daily Daily Check operation daily; tion apply Polaris dielectric grease to connector when replaced Tail lamp inspec- Daily Daily Check operation daily; tion apply Polaris dielectric grease to socket when...
  • Page 112 Due to the nature of the adjustments marked with a J on the , it is recommended that service be performed by following chart an authorized Polaris dealer. More often under severe use, such as dirty or wet " conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 113 MAINTENANCE Item Hours When Remarks Miles Engine Oil - Level/ 100 hrs Check Level Daily; " Change (4-Cycle) / 1000 months Break in Service at 1 miles month. Change oil more often in cold weather use. Oil Filter(4-Cycle) 100 hrs Replace with oil change "...
  • Page 114 Due to the nature of the adjustments marked with a J on the , it is recommended that service be performed by following chart an authorized Polaris dealer. More often under severe use, such as dirty or wet " conditions to purge water or dirt contamination from grease fittings and other critical components.
  • Page 115 MAINTENANCE Item Hours When Remarks Miles Radiator 100 hrs 12 Inspect/clean external months surface Cooling System 100 hrs 12 Inspect hoses months Spark arrestor 100 hrs 12 Clean out months Front hubs/fluid 100 hrs 12 " change (AWD) months Clutches (drive 100 hrs 12 Inspect, clean and driven)
  • Page 116 MAINTENANCE Lubrication Recommendations Item Lube Rec Method Frequency* 1. Engine Oil Polaris Fill oil tank. See page 58. As needed, (2-Cycle) Injection when refuel- 2.Engine OIl Polaris Add to proper level on dip- Check level (4-Cycle) Premium stick. See page 61.
  • Page 117 MAINTENANCE Lubrication Recommendations 4. Transmission (dipstick) Full Operating Range 4. Transmission (plug) 5. Front Gear Case Fill plug Fill plug 6. Front Prop Shaft (U-Joint) 7. Propshaft Yoke...

  • Page 118: Lubrication Recommendations

    MAINTENANCE Lubrication Recommendations 10. Front Grease+ Locate grease fitting and Every 3 Drive Axle (U grease with grease gun. months or Joint) (AWD 50 hours Models) 11. Ball Joint Locate fitting on back side of Every 3 Grease struts and grease with grease months or gun.
  • Page 119 MAINTENANCE Lubrication Recommendations 13. Counterbalance Dipstick 10. Axle Cardan Front Drive (AWD Models) 14. Steering Post Bushings 9. Demand 4 Hubs (4x4 only) Upper 9. 4 O’clock 12. Front A-Arm position Pivot Shaft 11. Ball Joint...
  • Page 120 + Grease every 500 miles, or before long periods of storage or after pressure washing, or after submerging in water. Always use Polaris Premium U-Joint Lube for maximum service of these driveline components (PN 2871515 3 oz.)(PN 2871551 14 oz.).
  • Page 121 MAINTENANCE Lubrication Recommendations 16. Swing Arm Bushings 15. Rear Axle Bearing INDEPENDENT REAR SUSPENSION 18. Lower Control 17. Upper Control 18. Lower Control 20. Rear Anti- 19. Rear Wheel Roll Bar Hub Bearing Carrier...
  • Page 122 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Servicing Servicing Remarks Interval Date Dealer Performed or Person First 5 Hrs. 25 Hrs. 50 Hrs. 75 Hrs. 100 Hrs.
  • Page 123 MAINTENANCE 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 pos- sible serious personal injury or death. Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit.
  • Page 124 Rear 1/2″ 50 Ft. Lbs. NOTE: All nuts that have a cotter pin installed must be ser- viced by an authorized Polaris Dealer. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. Service work must be performed by your...
  • Page 125 MAINTENANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension. Rear Spring Adjustment Rear Spring Adjustment NOTE: Accessory springs are available through your Polaris dealer.
  • Page 126 MAINTENANCE Side Panel Removal (Gen IV Models) Side panel removal may be difficult until the locking tabs and re- ceivers have been snapped and unsnapped a few times. 1. Remove seat. Grasp rear of side panel near rear cab. With a quick firm motion, pull the panel...
  • Page 127 MAINTENANCE Air Cleaner - 2 Cycle Engines Filter Removal and Service Procedure 1. Remove the ATV seat. 2. Unsnap the four clips holding the cover assembly to the air box. 3. Loosen clamp securing the filter and remove the filter. 4.
  • Page 128 MAINTENANCE Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you ob- serve the following practices. 1. Never immerse the filter in water since dirt can be transferred to the clean air side of the filter.
  • Page 129 MAINTENANCE Operation of your ATV without a breather filter can cause en- gine damage. Breather Filter and Hose - 4-Cycle Engines With Dry Sump* 1. Remove the clamps and pull the filter out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine.

  • Page 130: Steering Inspection

    The camber and caster are non-adjustable. Do not attempt to adjust the tie rod for toe alignment. Severe injury or death can result from improper adjustment. Contact your Polaris dealer. He/she has the training and tools to make these adjustments. Toe Alignment...
  • Page 131 MAINTENANCE Toe Alignment (cont.) 2. Place stands in front of the machine, perpendicular to the rear tires. 3. Tie an elastic string around the stands, making sure string just touches side surface of the rear tires on each side of machine and goes around the stands in front of the machine.

  • Page 132: Front Brake

    Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation. Use Polaris DOT 3 brake fluid (PN 2870990). D Check brake system for fluid leaks.
  • Page 133 Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right floorboard. All Polaris ATVs have hydraulic brake systems. The hydraulic auxiliary brake system will not re- quire adjustment.
  • Page 134 MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″...
  • Page 135 MAINTENANCE Oil Pump Adjustment Procedure - 250 Engines 1. Before adjusting the oil Cable Adjuster pump, check engine idle RPM and carburetor ad- justments which are found in the owner’s manual sup- plement. Locknut 2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16″...
  • Page 136 MAINTENANCE Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil res- ervoir and supply line have been completely run out of oil. In these cases, loosen the pump bleed screw one full turn.
  • Page 137 MAINTENANCE Engine Choke Adjustment 2-Cycle Engines When the choke is in the full off position, the choke plunger must be seated on the fuel passageway in the carburetor. If the plunger is not seated on the passageway, the engine will flood or run too rich, causing spark plug fouling and very poor engine perfor- mance.
  • Page 138 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 2 Cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by running vehicle approximately five min- utes.
  • Page 139 MAINTENANCE Choke Adjustment Procedure 4-cycle Engine Toggle Switch 1. Push choke knob to the full off position. 2. Slide boot off in-line cable adjuster sleeve. Loosen adjustment locknut on in- line cable adjuster. 3. Turn cable sleeve adjusting nut clockwise on in-line ad- juster until 1/8″...
  • Page 140 MAINTENANCE Choke Adjustment Procedure 4-cycle Engine Push/Pull Choke 1. Locate the boot behind the choke knob and pull it back. Loosen the friction nut 1 turn or until choke slides freely. Re-install boot. 2. Push the choke knob in to the full off position.
  • Page 141 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted as follows: 1. Warm up the engine by run- ning the vehicle approxi- mately five minutes. Idle Screw 2.

  • Page 142: Spark Plugs

    MAINTENANCE Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap. The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immedi- ately check the spark plug for correct color.
  • Page 143 MAINTENANCE Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every six months, whichever comes first.
  • Page 144 MAINTENANCE Oil Filter and Change (4-Stroke models with an external oil tank) 1. Place vehicle on a level surface. 2. Clean area around drain plug which is found at the bottom of the oil tank or on the bottom of the engine. 3.
  • Page 145 MAINTENANCE Oil Filter and Change (Cont.) (4-Stroke models with an external oil tank) 11. Lubricate O-Ring on new filter with a film of new engine oil. Check to make sure the O-Ring is in good condition. Also make sure the O-ring from the old filter is not still on the engine. 12.
  • Page 146 MAINTENANCE Oil Filter and Change Magnum 325 2x4, Magnum 325 4x4, Trail Boss Oil and Filter Change 1. Place vehicle on a level surface. Crankcase Drain 2. Run engine two to three minutes until warm. Stop engine. 3. Clean area around drain plug.
  • Page 147 Oil Filter and Change (Cont.) Magnum 325 2x4, Magnum 325 4x4, Trail Boss 12. Remove dipstick and fill sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place gear selector in neutral and set parking brake.
  • Page 148 O-ring is in good condition. 11. Install new filter and turn by hand until filter gasket contacts the sealing surface, then turn an additional 1/2 turn. 12. Remove dipstick and fill sump with 4.5 quarts (4.25L) of Polaris Premium 4 synthetic oil.
  • Page 149 MAINTENANCE Oil Filter and Change (Cont.) Xpedition 325 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks. 15. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.
  • Page 150 MAINTENANCE Oil Filter and Change Xpedition 425 1. Place vehicle on a level surface. Oil Drain 2. Run engine two to three minutes until warm. Stop engine. 3. Clean area around drain plug. 4. Place a drain pan beneath engine crankcase and remove drain plug.
  • Page 151 MAINTENANCE Oil Filter and Change (Cont.) Xpedition 425 12. Remove dipstick and fill sump with 5.5 quarts (5.2 l) of Polaris Premium 4 synthetic oil. 13. Shift machine into neutral and set parking brake. 14. Start the engine and let it idle for one to two minutes. Stop the engine and inspect for leaks.
  • Page 152 (1) and check the lubricant level. Use the il- lustration and the chart below to determine the correct fluid level. The correct transmission lubricant to use is Polaris Premium Syn- thetic Gearcase Lubricant (PN 2871478). Magnum 4x4 Shown Model Oil Level “A”...
  • Page 153 Catch and discard used oil properly. 4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93 kg-m). 5. Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant until oil reaches the bottom of the filler hole. 6. Check for leaks.
  • Page 154 With the ATV on a level surface, re- move fill plug dipstick and check the lubricant level. Lubricant should be kept at the full mark on the dipstick. The correct trans- mission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant (PN 2871478).
  • Page 155 MAINTENANCE 2x4 Models To check the level: 1. Remove fill dipstick and wipe clean. 2. Reinstall dipstick com- pletely, remove check the level. Add the proper lubricant as re- quired to bring level into operating range shown. To change lubricant: 1.
  • Page 156 2. Remove transmission drain plug side and drain the oil. Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add 32 oz. (948 ml) Polaris Premium Synthetic Gearcase Lubricant (PN 2871478 - 12 oz. bottle) to full mark on Full the fill plug/dipstick.
  • Page 157 MAINTENANCE Front Gearcase Lubrication The front gearcase fill plug is lo- cated as shown. The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. Type A - With the ATV on a level surface, remove fill plug and check the lubricant level.
  • Page 158 MAINTENANCE Rear Gearcase Lubrication With the ATV on a level surface, remove fill plug and visually in- spect the lubricant level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2) approximately 1 5/8″...
  • Page 159 MAINTENANCE Counter Balance Lubrication - 400 Engines 1. Counter Balance Drain 2. Crankcase Drain 3. Recoil Drain 4. Starter Pinion Drain The counter balance oil should be checked semi- annually and oil should be added or changed as nec- essary. The oil should be changed annually, espe- cially before off season storage.
  • Page 160 MAINTENANCE Procedure for Adding Oil 1. Remove seat and locate dipstick (1). 2. Remove dipstick. Oil level is shown on dipstick. 3. Add SAE 10W30 oil with a transmission fluid funnel until oil is at the proper level on the dipstick. If over- filled, excess oil will be ex- pelled through the vent...
  • Page 161 MAINTENANCE Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect ve- hicle handling which could cause an accident resulting in seri- ous injury or death. Follow the safeguards listed below to prevent this type of situation.

  • Page 162: Wheel Installation

    MAINTENANCE Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2.
  • Page 163 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed perma- nently greased pins and rollers. However, it is still necessary to lu- bricate the outer surfaces of the roller. Never wash the chain with a high pressure washer or gasoline.
  • Page 164 MAINTENANCE Rear Drive Chain Slack Adjustment (Models with Concentric Drive) Never adjust or operate the vehicle with the rear drive chain too loose or too tight as severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly for- ward to gain slack at the top side of the rear chain.
  • Page 165 MAINTENANCE Adjustment Procedure 1. Loosen chain guide. 2. Loosen two eccentric lock- ing bolts (2). 3. Loosen caliper mounting Rear Drive Chain Adjustment bracket bolts located under the axle. 4. Insert a pin punch through the sprocket hub and into the eccentric axle housing.

  • Page 166: Headlight Lamp Replacement

    MAINTENANCE Headlight Lamp Replacement Keep you headlights and taillights clean. Poor lighting while riding can result in an accident causing severe injury or death. Do not service while headlight is hot. Serious burns may result. Do not touch a halogen lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot which will shorten the life of the lamp.

  • Page 167: High Beam Headlight Adjustment

    MAINTENANCE High Beam Headlight Adjustment The headlight beam can be adjusted up and down. 1. Place the vehicle on a level surface with the headlight approxi- mately 25’ (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the head- light and make a mark on the wall at the same height.

  • Page 168: Headlight Adjustment

    MAINTENANCE Headlight Lamp Replacement (Trail Blazer) 1. Remove front cover and unplug the light harness. 2. Remove rubber cap from back of headlight to reveal retention screw. 3. Remove small phillips head screw, and carefully remove bulb from housing. 4. Insert new bulb into housing and tighten retention screw, install rubber cap.
  • Page 169 MAINTENANCE Headlight Lamp Replacement (Gen II) 1. Remove the seat. 2. Remove the plastic panel surrounding the upper por- tion of the gas tank by first re- moving the gas tank cap. 3. Remove the Phillips head screws on either side of the 3.
  • Page 170 MAINTENANCE Headlight Replacement (cont.) 9. Carefully unplug the socket from the lamp. Remove the panel and set it aside. 10. Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 11. Remove bolt and disengage the wire bail holding the headlight lamp in place and move it out of the way.
  • Page 171 MAINTENANCE Headlight Lamp Replacement (Gen IV Snap pins into tabs Position Slip O-Ring knob in over pin slot and secure in Adjustment Route indicator locking Knob Stop harness over tabs handlebar 1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod.
  • Page 172 MAINTENANCE High Beam Headlight Adjustment (Gen IV) The headlight beam can be adjusted to any position desired by turning the adjusting knob located on the bottom right side of the headlight pod. 1. Place the vehicle on a level surface with the headlight approxi- mately 25’...
  • Page 173 MAINTENANCE Headlight Housing Replacement 1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 2. Lift the pod lightly while depressing the tabs. 3. Remove the screw in the back of the headlight pod 4.
  • Page 174 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be re- placed. 1. From the rear of the taillight re- move two screws holding lens cover in place and remove lens cover. 2. Remove lamp (A) and replace it with recommended lamp.
  • Page 175 MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few pre- cautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be taken to avoid water damage to the wheel bearings, transmis- sion seals, body panels, brakes and warning labels.

  • Page 176: Storage Tips

    High pressure washers may force water past seals. Drain the recoil housing. Stabilize Fuel - Fill the fuel tank. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow instructions on the con- tainer for recommended amount. Carbon clean will also reduce the possibility of bacterial growth in the fuel system.
  • Page 177 MAINTENANCE * Fog The Engine - 2 Strokes - Polaris Fogging Oil (PN 2870791) follow directions on the can. 4-Strokes - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use a section of clear 1/4″ hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
  • Page 178 4. Treat the fuel system with Polaris Carbon Clean. 5. If Polaris fuel system additive is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline. to eliminate any fuel remaining in the carburetor, run the engine until it stops.

  • Page 179: Carburetor Adjustments

    Accessories There are a wide range of Polaris Accessories available for ATVs. Contact your Polaris dealer to find out about the accessories avail- able for your machine.

  • Page 180: Troubleshooting

    TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a Shift transmission to low range dur- pickup or tall trailer when ing loading of the ATV to prevent belt in high range. burning.
  • Page 181 Clutch malfunction. For inspection of clutch components, please contact your Polaris dealer. Poor engine performance. Fouled plugs, foreign material in gas tank, fuel lines, or carburetor. Con- tact you dealer for further service in- formation.
  • Page 182 The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START...
  • Page 183 TROUBLESHOOTING ENGINE STOPS OR LOSES POWER Spark Plug Engine No Fuel Fouled Overheated Turn Fuel Air Filter Clean Radiator Valve to “Res” Clogged screen and Radiator Core Fuel Vent Reverse Speed (liquid cooled Line Kinked Limiter models) or Plugged Malfunction Clean Engine Electronic Water in Fuel...

  • Page 184: Warranty

    Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects.
  • Page 185 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.
  • Page 186 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 war- ranty service you must present your copy of the Warranty Registra- tion form to the dealer.

  • Page 187: Index

    INDEX Air Cleaner ... 116-117 Engine Idle Rpm Air Filter, Scramblert 500 Adjustment ..128-130 All Wheel Drive ... Filter Change .
  • Page 188 INDEX Spark Plugs ... . . Transmission Starting A Cold Engine ..Lubrication ..141- 143 Starting The Engine ..65-66 Transmission Oil Changing Steering Inspection...
  • Page 189 WARNING Read and understand all warning labels and Owner’s Manual before operation. Severe injury or death can result from ignoring warnings or improper use. Never permit a guest to operate this vehicle unless the guest has read and understands all warning labels and the Owner’s Manual.

This manual is also suitable for:

Trail boss 3252001 atv

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