Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this; WARNING
A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance. The engine exhaust from this product contains chemicals known to cause cancer, birth def...
Page 6 - WELCOME; Polaris Recreational Vehicles; RANGER
3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S RANGER utility vehicles S V...
Page 7 - VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the
4 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition swi...
Page 8 - TABLE OF CONTENTS
5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 4 . . . . . . . . . . . . . . . SAFETY 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 32 . . . . ....
Page 9 - SAFETY; Safety Decals and Locations; ATV, always read and follow the instructions of the decals
6 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 de...
Page 10 - ATTENTION
7 SAFETY Safety Decals and Locations ATTENTION S Operation of this vehicle without the air filter element will severely damage the engine. S Clean pre-filter element often, more frequent cleaning required in dusty conditions. Do not operate vehicle without pre-filter. 7172921 IMPROPER TIRE PRESSURE ...
Page 11 - NO STEP
8 SAFETY Safety Decals and Locations S 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. S Max Rack Loads: Front 100 lbs. (45 kg) Rear 200 lbs. (91 kg) 7172749 S Moving parts hazard under belt-clutch guard. To preve...
Page 13 - Safe Riding Gear
10 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...
Page 14 - Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions
11 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can o...
Page 15 - The following signal words and symbols appear throughout this; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution; IMPORTANT; note
12 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manua...
Page 16 - Serious injury or death can result if you do not follow these; Take a training
13 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an...
Page 18 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
15 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test the brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to ...
Page 19 - not know how to operate the ATV properly in different situations; abilities, or judgment needed to operate an ATV safely and could
16 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe 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 HAZARDB...
Page 22 - operator judgment. Reaction time may be slower and operator; control of the ATV, which can result in an accident causing severe; the chance of an accident,
19 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.Consuming alcohol and/or...
Page 23 - schedules described in the owner’s manual.; come into contact with the rear wheels and lead to accident or
20 SAFETY Operator Safety WARNING POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure ...
Page 25 - Never operate the ATV on hills steeper than 25
22 SAFETY Operator Safety WARNING POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds bef...
Page 26 - cause loss of control or
23 SAFETY Operator Safety WARNING POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully be...
Page 28 - hills could cause loss of control or
25 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning te...
Page 29 - or improperly dismounting
26 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the bra...
Page 30 - trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.
27 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fall...
Page 33 - cargo or pulling a trailer.
30 SAFETY Operator Safety WARNING POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for t...
Page 35 - FEATURES AND CONTROLS; Engine Electrical Switches; OFF
32 FEATURES AND CONTROLS Engine Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch (1) - This vehicle is equ...
Page 36 - Throttle Lever; Engine speed and vehicle movement
1 33 FEATURES AND CONTROLS WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle pr...
Page 37 - Light Switches; ON; Brake Lever
34 FEATURES AND CONTROLS Light Switches The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO. NOTE: The lights won’t work unless the key is in the ON position and the auxiliary shut-off switch is in the RUN position. WARNIN...
Page 38 - Master Cylinder; eye
35 FEATURES AND CONTROLS Master Cylinder The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid lev...
Page 39 - Parking Brake; Operating the ATV while the parking brake is engaged could; Setting the Parking Brake
36 FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Setting the Parking Brake 1. Place the transmission in park.2. Squeez...
Page 40 - Auxiliary Brake; Aggressively applying the auxiliary brake when backing down a; reduce; Brake Fluid Level; Fuel Tank
37 FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. T...
Page 41 - Automatic Transmission Gear Selector; to activate the high/park lock-out mechanism. When shifting out of; Shifting gears with the engine speed above idle or while the; Belt Life
38 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.H: High Gear L: Low Gear N: Neutral R: Reverse P: ParkTo shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out m...
Page 42 - The override switch allows activation of AWD in reverse if the; Engaging the Front Gearcase; Switching to AWD while the rear wheels are spinning may cause
39 FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4-wheel drive ATVs are equipped with a unique, Polaris-exclusive, On-Demand All Wheel Drive system, which is activated by the AWD switch (1) on the right handlebar. When the switch is off, the ATV is in two-wheel drive at all times. When ...
Page 43 - Instrument Cluster; speed from the right front wheel. The instrument cluster measures; High water pressure may damage ATV components. Wash the
40 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 s...
Page 44 - Rider Information Center; If the instrument cluster fails to illuminate, a battery; Engine Hour Display Indicator
41 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instru...
Page 45 - mode
42 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode...
Page 46 - Diagnostic Mode; Any movement of the tires will also take the machine out of
43 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.To leave the diagno...
Page 47 - If you scroll past the intended number, hold the button down
44 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory...
Page 48 - Special EFI Diagnostic Mode
45 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Special EFI Diagnostic Mode The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module:1. Place the transmission in ...
Page 49 - OPERATION; Fuel Safety; Gasoline is highly flammable and explosive under certain; exhaust fumes are poisonous and can cause loss of; The engine exhaust from this product contains chemicals known
46 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...
Page 50 - the procedures for a proper break-in. Careful treatment of a new; SH; if necessary to maintain the level between the safe and add marks.
47 OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatme...
Page 51 - If a proper inspection is not done before each use, severe injury
48 OPERATION Pre-Ride Inspection WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it’s in proper operating condition. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...
Page 52 - Starting the Engine; Cold Weather Operation
49 OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface with the transmission in PARK. 2. Lock the park brak...
Page 53 - Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Use low forward gear when hauling or towing heavy cargo to extend
50 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner’s manual and on the safety decals...
Page 55 - Driving Safely; Driving Procedures
52 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...
Page 56 - Making Turns; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
53 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slig...
Page 57 - Driving on Slippery Surfaces
54 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high lev...
Page 58 - Traveling Uphill; include quick dismounting of the vehicle.; terrain. Improper procedure could cause loss of control or
55 OPERATION Driving Safely Traveling Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening.6. Remai...
Page 59 - Sidehilling; control or vehicle overturn, resulting in severe injury or death.; hill while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
56 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilli...
Page 60 - Traveling Downhill; Excessive speed when traveling downhill can cause loss of; Applying the brakes too firmly may cause the rear
57 OPERATION Driving Safely Traveling Downhill WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death. When traveling downhill, follow these precautions:1. Transfer your weight to the rear.2. Drive straight down the hill.3. Slow down. Squeeze the brake ...
Page 61 - Turning Around on a Hill; Improper hill climbing procedures could cause loss of control or; slowly
58 OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.Avoid climbing steep hills (25 _ maximum). Use extreme caution when operating on hills, and follow proper operating procedures ...
Page 62 - Driving Through Water; critical
1 59 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where bot...
Page 63 - Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact
60 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you’re traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. ...
Page 64 - Driving in Reverse; apply the brakes
61 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...
Page 65 - Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
62 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.2. Place the transmission in park.3. Set the parking brake.4. Always block the rear wheels on the downhill side as shown.
Page 66 - EMISSION CONTROL SYSTEMS; Noise Emission Control System
63 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordanc...
Page 67 - MAINTENANCE AND LUBRICATION; Accessories; Severe Use Definition; Maintenance Chart Key
64 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio...
Page 68 - Periodic Maintenance Chart
65 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) J Steering -- Pre-Ride -- Make adjustments as need- ed See Pre Ride Checklist " F...
Page 71 - Periodic Maintenance Record; Use the following chart to record periodic maintenance.
68 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks
Page 72 - Lubrication Guide; Lubrication Guide Key; More often under severe use, such as wet or dusty conditions
69 MAINTENANCE AND LUBRICATION Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Guide Key " More often under s...
Page 73 - Premium 4 Synthetic Lubricant; Mixing brands or using a non-recommended oil may cause
70 MAINTENANCE AND LUBRICATION Premium 4 Synthetic Lubricant Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance a...
Page 74 - Oil Level; upper
71 MAINTENANCE AND LUBRICATION Oil Level The oil dipstick and fill tube (1) is located on the engine and is accessible on the left side of the ATV. 1. Position the ATV on a level surface.2. Start the engine and let it idle for 20-30 seconds, then stop the engine. 3. Lift the lever lock (2) to remove...
Page 75 - Oil and Filter Change; Hot oil can cause serious burns to skin. Do not allow hot oil to
72 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to come into contact with skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Always change the oil filter w...
Page 76 - Transmission Oil; Oil Check
73 MAINTENANCE AND LUBRICATION Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the transmission oil level at the bottom of the fill plug hole (1). We recommend the use of Polaris Premium AGL Synt...
Page 77 - Front Gearcase Oil; Premium Demand Drive Hub Fluid
74 MAINTENANCE AND LUBRICATION Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand ...
Page 78 - Rear Gearcase Oil
2 1 3 75 MAINTENANCE AND LUBRICATION Rear Gearcase Oil The rear gearcase fill plug (1) is located on the rear of the gearcase. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 64. Maintain the rear gearcase oil level (2) even...
Page 79 - Engine Cooling System; Radiator Coolant Level
76 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Pola...
Page 80 - Coolant Level; The recovery bottle (1) is located on the; Cooling System Operation; Some coolant level drop on new vehicles is normal as the
77 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 81.Maintain the coolant level between the minimum and maximum marks on the bottle (when...
Page 81 - Brakes; The front and rear brakes are hydraulic disc brakes, activated by
78 MAINTENANCE AND LUBRICATION Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more often if b...
Page 82 - damage and looseness.; Replace brake pads when they; main brake system. Should the main system fail, the rear brake can be; Since this is a rear brake only, it will not be as effective as
79 MAINTENANCE AND LUBRICATION Brakes 2. Check the brake system for fluid leaks.3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear, damage and looseness. 5. Check the security and surface condition of the disc. NOTE: Replace brake pads when they are worn to ...
Page 83 - Toe Alignment; Steering Assembly
80 MAINTENANCE AND LUBRICATION Toe Alignment WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Use the following procedure to check the toe ali...
Page 84 - Side Panel Removal; motion, pull the panel outward to disengage the side panel from the; Footwell Removal; on the bottom of the footwell.
81 MAINTENANCE AND LUBRICATION Side Panel Removal 1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. 3. Pull the panel downward and rearward to remove it from the ATV.4. Reinstall the side...
Page 85 - Operating your ATV with worn tires, improperly inflated tires,; Tire Tread Depth; Always replace tires when tread; Wheel Removal; Stop the engine, place the transmission in
82 MAINTENANCE AND LUBRICATION WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.Maintain proper tire pressure as described on the decal...
Page 86 - Wheel Installation; Wheel Nut Torque Specifications; Location; Front Wheel Hub Tightening
83 MAINTENANCE AND LUBRICATION Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed....
Page 87 - Filter Systems; Air Filter Service
84 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service 1. Remove the seat, release the air box cover clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then r...
Page 88 - Lights; When servicing a halogen lamp, don’t touch the lamp with bare; Poor lighting while driving can result in severe injury or death.; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight; Make sure the tab on the lamp locates properly in the
85 MAINTENANCE AND LUBRICATION Lights When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillig...
Page 89 - High Beam Adjustment; Include rider weight on the seat when measuring.; Low Beam Adjustment
86 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. 2. Measure the distanc...
Page 90 - Headlight Housing Replacement; The distance from the; Adjust the headlight aim by
87 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer...
Page 91 - Lower Headlamp Removal / Installation
1 1 2 2 1 88 MAINTENANCE AND LUBRICATION Lights Lower Headlamp Removal / Installation 1. Turn the back of the headlight harness (1) counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly ...
Page 92 - Spark Plugs; Spark Plug Removal and Replacement
89 MAINTENANCE AND LUBRICATION Spark Plugs S Use RC7YC spark plugs. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 18 ft. lbs. (24 Nm). CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Spark plug condition i...
Page 93 - Vehicle Immersion; Check the air box for any water and dry it if it’s wet.
90 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it’s impossible to take your ATV to a dealer before starting it, follow...
Page 94 - Spark Arrestor
1 2 91 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow comp...
Page 95 - PVT System; pinch; When To Use Low Range vs. High Range; Low Range
92 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinc...
Page 96 - PVT Drying; the PVT system. Use the following instructions to dry it out before
93 MAINTENANCE AND LUBRICATION PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precisio...
Page 97 - Battery; in an explosion and cause serious injury or death. When; Battery Removal; initial use. Using a new battery that has not been fully charged can
94 MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative...
Page 98 - Battery Storage; The following battery charging instructions apply only to the
95 MAINTENANCE AND LUBRICATION Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it’s fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rec...
Page 99 - Battery Charging; Always verify battery condition before and 1-2 hours after the
96 MAINTENANCE AND LUBRICATION Battery Battery Charging NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time* (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at 3...
Page 100 - Cleaning and Storage; Cleaning the ATV; Waxing the ATV
97 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 107 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an ...
Page 101 - Storage Tips; Starting the engine during the storage period will disturb the; Clean the Exterior
98 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make necessary repairs and then clea...
Page 102 - Fog the Engine; Do this carefully! If you miss the plug holes, oil will drain from; Inspect and Lubricate; Do not use plastic or coated materials. They do not allow
99 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Fog the Engine 1. Treat the fuel system with Polaris Carbon Clean, following the instructions on the can. Run the engine for several minutes so the Carbon Clean reaches the injectors. Turn the engine off. 2. Remove the spark plugs and ...
Page 103 - Removing Corrosion; Transporting the ATV
100 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud ...
Page 104 - ADJUSTMENTS; Camber and Caster
101 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (1) either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris deal...
Page 105 - Throttle Body/Idle RPM; satisfactory, please see your Polaris dealer for adjustment.; Throttle Cable Freeplay; freeplay is achieved at the; While adjusting freeplay, be sure to flip the throttle lever back; they touch at the midpoint of the adjuster.
102 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Slide the boots (1) off the inline cable adjuste...
Page 106 - TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause
103 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline When starting out on an incline, use low rang...
Page 107 - solutions using the following charts.; Engine Doesn’t Turn Over
104 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.8 VDC Loose battery connections Check a...
Page 108 - Engine Backfires
105 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...
Page 109 - Engine Stops or Loses Power; Engine Overheating
106 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, cl...
Page 110 - POLARIS PRODUCTS
107 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (q...
Page 111 - SPECIFICATIONS
108 SPECIFICATIONS SPORTSMAN 800 EFI Gross Vehicle Weight 1240 lbs. (563 kg) Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Rear Gearcase Oil Capacity 10 oz. (300 ml) Front Gearcase Oil Capacity 5 oz. (150 ml) Transmission Oil Capacity 15 oz. (450 ml) Coolant Capacity 3.2 qts. (...
Page 112 - Clutching Chart; EBS models require no helix / spring adjustment
109 SPECIFICATIONS SPORTSMAN 800 EFI Transmission Automatic EBS w/E-Z Shift H/L/N/R/P Gear Reduction (Low) 7.49:1 Gear Reduction (Reverse) 5.11:1 Gear Reduction (High) 2.70:1 Drive Ratio (Front) 3.82:1 Drive Ratio (Final) 3.10:1 Tires / Pressure (Front) Polaris PXT 26 x 8 - 12 / 5 psi Tires / Pressu...
Page 113 - WARRANTY; LIMITED WARRANTY
110 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for f...
Page 115 - HOW TO OBTAIN WARRANTY SERVICE; Engine Oil
112 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states ...
Page 116 - Exported Vehicles; How to Get Service; In the Country where your vehicle was purchased:
113 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for expor...
Page 117 - If Purchased From A Private Party:; Notice; chased, and you have not followed the procedure set out above, your
114 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 th...
Page 118 - INDEX
115 INDEX A Accessories 64 . . . . . . . . . . . . . . . . . . . ADJUSTMENTS 101-102 . . . . . . . . . . Age Restrictions 11 . . . . . . . . . . . . . . . Air Filter Service 84 . . . . . . . . . . . . . . . All Wheel Drive 39 . . . . . . . . . . . . . . . Automatic Transmission 38 . . . . . . . . . ...
Polaris 600 XC
Manual
Polaris 800 PRO RMK
Manual
Polaris 9922460
Manual
Polaris Trail Touring Deluxe
Manual
Polaris 600 IQ ES
Manual
Polaris 9921309
Manual
Polaris RZR S
Manual
Polaris FST Classic
Manual
Polaris Predator 90
Manual
Polaris 200
Manual
Polaris 9922551
Manual
Polaris 6X6
Manual
Polaris 9919412
Manual
Polaris 2010 99 Ranger
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Polaris 9920632
Manual
Polaris RZR
Manual