Polaris 9920783 - Manuals

5 TABLE OF CONTENTS KNOW YOUR VEHICLE 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 48 . . . . . . . . . . . . . ...

6 KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others, and the protection of our environment. Read and understand your owner’s manual, which includes valuable information about all aspects of your vehicle, including safe operating proc...

8 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...

12 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. 1. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds establis...

14 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious 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 ...

15 SAFETY Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV...

16 SAFETY Operator Safety The following two pages identify signal words and symbols that appear in this manual. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, a...

17 SAFETY Operator Safety CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. CAUTION A caution indicates a situation that may result in damage to the vehicle. NOTE: A note will alert you to important information or instruc...

18 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 de- scribed. S Never operate ...

22 SAFETY Operator Safety S Avoid operating the ATV through deep or fast-flowing water. If it’s unavoid- able, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward mo- tion. Do not make sudden turns or stops, and do not make sudden throttle cha...

23 SAFETY Operator Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifica...

24 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV without proper instruction.WHAT CAN HAPPEN: The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZ...

25 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to follow the skill and experience recommendations for this ATV.WHAT CAN HAPPEN: Severe injury and/or death could occur if a beginner or inexperienced driver operates this ATV.HOW TO AVOID THE HAZARD: Only operators with advanced skills and...

29 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV on public streets, roads or highways.WHAT CAN HAPPEN: The ATV could collide with another vehicle.HOW TO AVOID THE HAZARD: Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many state...

32 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Attempting jumps and other stunts.WHAT CAN HAPPEN: Attempting stunts increases the chance of an accident, including an overturn.HOW TO AVOID THE HAZARD: Never attempt jumps or other stunts. Avoid exhibition driving.

33 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Failure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPEN: Poor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARD: Always inspect your ATV before each use to make...

34 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Removing hands from the handlebars or feet from the footpegs during operation.WHAT CAN HAPPEN: Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.If the operator’s foot ...

37 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Turning improperly.WHAT CAN HAPPEN: Improper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARD: Always follow proper procedures for turning as described in the owner’s manual. Practice turning at slow spe...

41 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Stalling, rolling or improperly dismounting while climbing a hill.WHAT CAN HAPPEN: The vehicle could overturn.HOW TO AVOID THE HAZARD: Maintain steady speed when climbing a hill.If all forward speed is lost: Keep your weight uphill. Apply front bra...

42 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Improperly operating over obstacles.WHAT CAN HAPPEN: Operating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARD: Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks a...

44 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating this ATV with improper tires, or with improper or uneven tire pressure.WHAT CAN HAPPEN: Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident.HOW TO AVOID THE HAZARD:...

45 SAFETY Operator Safety WARNING POTENTIAL HAZARD: Operating the ATV with improper modifications.WHAT CAN HAPPEN: Improper installation of accessories or modification of the ATV may cause changes in handling, which could lead to an accident.HOW TO AVOID THE HAZARD: Never modify the ATV through impr...

47 SAFETY Operator Safety WARNING Operating a damaged ATV can result in an accident with serious injury or death. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. WARN...

48 FEATURES AND CONTROLS Engine Electrical Switches 1 2 3

49 FEATURES AND CONTROLS Engine Electrical Switches 1 . Start Button - The start button engages the starter. Always release the start button as soon as the engine starts. 2 . Engine Stop Switch - The purpose of this switch is to provide the operator with a quick means of engine shutdown in case of a...

50 FEATURES AND CONTROLS Instrumentation An illuminated light in the indicator window will alert you to the following conditions.1. Hot engine2. Reverse gear is selected3. Neutral gear is selected N R 3 1 2

51 FEATURES AND CONTROLS Lights WARNING Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death. Your ATV is not equipped with highway-approved lights. It’s designed for and must be used for off-road use only . Use caution and drive at r...

52 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 prob...

53 FEATURES AND CONTROLS Throttle Lever Electronic Throttle Control This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle ...

54 FEATURES AND CONTROLS Foot Brake The foot brake (1) operates the rear brakes. It’s located in front of the right-hand footpeg (2). If the rear wheels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding.Check the brake fluid level frequently for the f...

55 FEATURES AND CONTROLS Brake Lever The brake lever operates the front brakes. It’s located on the right handlebar. Squeeze the brake lever toward the handlebar to engage the front brakes. These brakes are hydraulically activated disc type brakes.Always test brake lever travel and master cylinder f...

56 FEATURES AND CONTROLS Master Cylinder The master cylinder (1) is on the right-hand handlebar. Check the brake fluid level before each ride. The fluid level can be seen through thesight glass (2) on the side of the master cylinder.Maintain the fluid level at or slightly above the mark (3) near the...

58 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. Locking the Parking Brake 1. Place the transmission in first gear.2. ...

59 FEATURES AND CONTROLS Parking Brake Important Safeguards S The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a...

60 FEATURES AND CONTROLS Fuel Tank The fuel tank filler cap is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel. Fuel Filter The fuel valve has an internal fuel filter. Do not attempt to clean t...

61 FEATURES AND CONTROLS Fuel Valve The fuel valve (1) is located on the left side of the ATV. It has three positions:OFF: For vehicle storage and when transporting.ON: For normal operation.RES: For reserve supply if main supply is exhausted. NOTE: There’s about a 5 to 8 mile (8 to 13 km) range on r...

62 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. The choke knob (1) is located on the left side of the vehicle.Refer to the engine starting procedure on page 72 for correct choke and throttle settings during starting. 1

63 FEATURES AND CONTROLS Manual Shift Shift Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the transmission to the next gear in the shifting sequence. The pedal automatically returns to a horizontal position when released.To upshift to a ...

64 FEATURES AND CONTROLS Manual Shift Shifting Gears NOTE: Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped position, place the transmission in neutral.2. Squeeze and hold the brake lever. NOTE: Do not squeeze the throttle lever. 3. Squeeze the clutch leve...

65 FEATURES AND CONTROLS Manual Shift Reverse Lock-Out Switch The reverse lock-out switch (1) prevents the operator from shifting into reverse unintentionally.1. Place the transmission in first gear. See page 63. 2. Push the lock-out lever forward toward the handlebar to unlock the transmission. 3. ...

66 FEATURES AND CONTROLS Manual Shift Deceleration To slow or stop the ATV, release the throttle lever and apply the brakes smoothly and evenly. As the vehicle slows and engine RPM decreases, disengage the clutch and shift to a lower gear. NOTE: Be sure the engine RPM has sufficiently decreased befo...

67 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenev- er handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in o...

69 OPERATION Break-In Period 1. Fill the fuel tank with gasoline. See page 60.2. Check the oil level on the dipstick. See page 103. Add oil if necessary to maintain the level between the safe and add marks. 3. Allow the engine sufficient time to warm up before operating.4. Drive slowly at first. Sel...

71 OPERATION Pre-Ride Inspection Pre-Ride Checklist See Page Frame nuts, bolts, fasteners Inspect, ensure tightness -- Fuel and oil Ensure proper levels 103 Coolant level (if applicable) Ensure proper level 112 Coolant hoses (if applicable) Inspect for leaks -- Throttle Ensure proper operation 52, 1...

72 OPERATION Starting a Cold Engine The engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in a...

73 OPERATION Starting a Cold Engine 3. Sit on the ATV. Pull the choke knob (1) out until it stops. NOTE: If the knob doesn’t stay where positioned, increase the tension by rotating the tension adjusting nut clockwise. FULL ON HALF ON OFF NOTE: The choke can be adjusted gradually, depending on how mu...

74 OPERATION Starting a Cold Engine NOTE: If starting the engine while in neutral, the neutral indicator light should be on. If it isn’t, disengage the clutch and shift the foot pedal to find neutral. See page 63. If starting the engine while in gear, apply the hand brake and squeeze the clutch leve...

75 OPERATION Starting a Warm Engine Follow the procedure for starting a cold engine, but do not use the choke.If the engine has cooled to a point where it does not readily start, intermittent use of the choke (pulled half way out) may be necessary.If you believe the engine is over-choked when warm, ...

76 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footpegs and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. See page 64. 3. Check your surroundings and determine your path of travel. 4. Release the...

77 OPERATION Driving Safely Making Turns Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance than the inside wheel when turning, and the inside tire slips traction slightly. To turn, steer in...

78 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. Maintain a high level of alertness, reading the trail and avoiding quick...

79 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footpegs and transfer your weight forward. 4. Proceed at a steady rate of speed and throttle opening. 5. Be al...

80 OPERATION Driving Safely Driving Across Hills 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. ...

81 OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Shift to the lowest gear possible while maintaining a safe speed. 5. Apply the foot brake slightly to aid ...

82 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...

83 OPERATION Driving Safely Turning Around on a Hill 5. Staying uphill of the ATV, turn the handlebars full left. Reach across the handlebar and apply the front brakes to unlock the parking brake. 6. With the front brakes applied, pull in the clutch lever. Use the brakes to slowly allow the vehicle ...

84 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 first gear. 3. Lock the parking brake.4. Always block the rear wheels on the downhill side. See illustration. 5...

85 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. N...

86 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the level of the footpegs (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing. 2. Choose a crossing where both ba...

88 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Avoid backing downhill.2. Back slowly.3. Apply the brakes lightly for stopping. 4. Avoid turning at sharp angles.5. Never open the throttle suddenly while backing.

89 OPERATION Driving Safely Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle.Drive slowly. Avoid backing on inclines. Avoid turning at sharp angles....

90 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...

91 EMISSION CONTROL SYSTEMS Crankcase Emission Control System This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system. Exhaust Emission Control System The emissions from th...

92 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the following pages. A tool kit is provided in the storage com...

93 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load opera- tion S Extended idle S Short trip cold weather operation Inspect, clean, lubricate, adjust and re...

94 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule WARNING Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services. Maintenance Chart Key " Perform these procedu...

95 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Brake systems/fluid -- Pre-Ride -- Inspect; maintain fluid between fill lines Tires -- Pre-Ride -- Inspect Wheels/lug nuts -- Pre-Ride -- Inspect; tighten Fra...

102 MAINTENANCE AND LUBRICATION Lubrication Recommendations Performance Synthetic 4-Stroke (PS-4) Oil Polaris highly recommends the use of Polaris PS-4 or a similar oil designed for use in 4-stroke manual clutch ATV and motorcycle applications. PS-4 has been specifically formulated for use in high p...

103 MAINTENANCE AND LUBRICATION Engine Oil Level Check the oil level before each use of the vehicle. The dipstick (1) is located on the left side of the ATV.1. Position the ATV on a level surface.2. Start the engine and let it idle for one minute.3. Stop the engine and remove the dipstick. Wipe it d...

104 MAINTENANCE AND LUBRICATION Engine Oil Level If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and...

105 MAINTENANCE AND LUBRICATION Oil and Filter Change CAUTION If the ATV is left without oil in the system for extended periods, the oil pump may lose its prime, which could result in engine damage. Do not allow the vehicle to be without oil and filter overnight. Always replace the oil and filter wi...

106 MAINTENANCE AND LUBRICATION Oil and Filter Change 1. Position the vehicle on a level surface.2. Clean the area around the oil tank (1) and crankcase (2) drain plugs with clean shop towels. 3. Run the engine for two to three minutes until warm, then stop the engine. 4. Place a drain pan beneath t...

107 MAINTENANCE AND LUBRICATION Oil and Filter Change 7. Place a drain pan beneath the crankcase and remove the drain plug.8. Allow the oil to drain completely.9. Replace the sealing washer and reinstall the plug. Torque to 14 ft. lbs. (19 Nm).10. Place shop towels beneath the oil filter.11. Remove ...

108 MAINTENANCE AND LUBRICATION Oil and Filter Change 14. Replace the o-ring in the cover.15. Lubricate the gasket on the new filter with a film of fresh engine oil.16. Reinstall the spring and install the new filter with the open end facing outward.17. Install the cover and torque the bolts to 72-7...

109 MAINTENANCE AND LUBRICATION Oil and Filter Change 18. Remove the dipstick and fill the oil tank with the recommended oil.19. Place the transmission in neutral. Lock the parking brake.20. Prime the oil pump using the procedure on page 110 . Then stop the engine and inspect for leaks. 21. Re-check...

110 MAINTENANCE AND LUBRICATION Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.1. Clamp or pinch off the vent line (1) approximately 2 I (5 cm) from the oil tank. 2. Run the engine for 5-10 seconds ...

111 MAINTENANCE AND LUBRICATION Engine Cooling System The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.To ensure that the coolant maintains its ability ...

112 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the right side of the vehicle under the front fender. The fluid level must be maintained between the FULL (2) and ADD (3) marks on the side panel (when the fluid is cool).As coolant operating te...

113 MAINTENANCE AND LUBRICATION Engine Cooling System WARNING Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the cap. Radiator Coolant Level This procedure is required only if the cooling system ha...

114 MAINTENANCE AND LUBRICATION Air Filter Systems 1. Unlatch and remove the seat.2. Release the two airbox cover clips (1) and rotate the cover rearward to remove it. 3. Remove the air filter retaining screw (2).4. Loosen the filter clamp (3).5. Remove the main air filter (4).6. Remove the pre-filt...

115 MAINTENANCE AND LUBRICATION Air Filter Systems 9. Wash the main filter element (4) without removing it from the internal filter cage. Rinse and let dry. 10. Apply a commercially available foam filter lubricant to the foam filter.11. Reinstall all components.12. Check the hoses for cracks, deteri...

116 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 tailli...

117 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement 1. Remove the wire harness connector from the back of the headlight. 2. On the left headlamp, grasp the bulb housing and turn it counterclockwise (1) to remove the bulb. On the right headlamp, turn the bulb housing clockwise (2) to re...

118 MAINTENANCE AND LUBRICATION Lights Headlight Assembly Replacement 1. Remove the wire harness connector from the headlights.2. Remove the front cab (see page 121).3. Remove the small adjuster bracket (1). Install it on the new lamp.4. Remove the large pivot bracket (2) and remove the headlamp.5. ...

119 MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the ATV on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engi...

120 MAINTENANCE AND LUBRICATION Lights Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle.1. Turn the ignition key on.2. Lightly apply and release the foot brake several times. A properly operating rear brakelight will immediately flash on and off w...

121 MAINTENANCE AND LUBRICATION Front Cab Removal 1. Remove the screws (1) from the left and right cab mounts. 2. Remove the wire harness connector from the cab. The connector is located under the left fender. 3. Remove the fuel tank cover screws (2).4. Remove the four side panel screws (3).5. Gentl...

122 MAINTENANCE AND LUBRICATION Rear Cab Removal 1. Unlatch and remove the seat.2. Remove the two lower bolts (1) on the rear fenders of the cab and the two bolts (2), washers and grommets (3) on the top of the cab. 3. Remove the cab. 3 2 1

123 MAINTENANCE AND LUBRICATION Spark Plugs S Use NGK DCPR8E spark plugs. S Proper electrode gap is .035 ″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm). CAUTION Using non-recommended spark plugs may result in serious engine damage and may void your emission-related warranty. Always use Polar...

124 MAINTENANCE AND LUBRICATION Spark Plugs 1. Normal The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white....

125 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 1. Remove the side panels and front cab (see page 121).2. Turn the fuel valve off. WARNING A hot ember on the ATV could cause fuel to ignite. Allow all components to cool sufficiently before accessing the spark plug. Alwa...

126 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 3. Move the fuel valve hose clamp (1) forward and gently remove the hose from the fuel valve fitting on the gas tank. 4. Remove the vent hose (2) from the steering post, taking note of the hose routing for reinstallation....

127 MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Removal and Replacement 5. Remove the tank mounting bolt (3) at the rear of the gas tank.6. Move the tank rearward and upward over the engine. Slowly remove the tank and be careful not to catch any hoses, wires or other components. Place the tan...

128 MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out WARNING Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components.Wear eye protection and gloves.Never run the engine in an e...

129 MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out Periodically clean the spark arrestor to remove accumulated carbon. Your vehicle has either an end cap-type arrestor or a set screw-type arrestor. Perform the appropriate clean-out procedure for your arrestor type. End Cap-Type Arrestor 1. Rem...

130 MAINTENANCE AND LUBRICATION Spark Arrestor Clean-Out Set Screw-Type Arrestor 1. Remove the bolt (1) and remove the arrestor (2) from the end of the muffler. 2. Use a non-synthetic brush to clean the arrestor screen (3). A synthetic brush may melt if components are warm. If necessary, blow debris...

131 MAINTENANCE AND LUBRICATION Vehicle Immersion If your ATV has been submerged or overturned in water deeper than the footpeg level, it’s critical to dry it promptly and properly before starting the engine. CAUTION Do not start the engine after an ATV has been in water that exceeds the recommended...

133 MAINTENANCE AND LUBRICATION Vehicle Immersion 6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer ejecting from the spark plug hole. 7. Check the oil level on the dipstick. If the level is higher than the pre-ride inspection level, ...

134 MAINTENANCE AND LUBRICATION Battery The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. Keep battery terminals and connections free of corrosion. If cleaning is necessa...

135 MAINTENANCE AND LUBRICATION Battery Storage When the vehicle is placed in storage for three months or more, the battery should be removed and stored out of the sun in a cool, dry place. Test and recharge the battery monthly and before reusing. Battery Removal 1. Remove the front cab (see page 12...

136 MAINTENANCE AND LUBRICATION Battery Installation 1. Place the battery in the battery holder.2. Connect and tighten the red (positive) cable first, then connect and tighten the black (negative) cable. 3. Attach the hold-down strap and reinstall the front cab.4. Verify that cables are properly rou...

137 MAINTENANCE AND LUBRICATION Battery Charging (Sealed Battery) The battery included with your ATV is sealed and the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully charged battery will register 12.8 V or higher. If the voltage is less than 12.8 volts,...

138 MAINTENANCE AND LUBRICATION Battery Charging (Sealed Battery) When using an automatic charger such as the Polaris Battery Tender t , refer to the manufacturer’s instructions for recharging. When using a constant current charger, use the guidelines on the following page for recharging. WARNING An...

140 MAINTENANCE AND LUBRICATION Tires 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 th...

141 MAINTENANCE AND LUBRICATION Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (3 mm) or less. See illustration. Wheel Removal 1. Stop the engine, place the transmission in gear and lock the parking brake. 2. Loosen the wheel nuts slightly.3. Elevate the side of the vehicle ...

142 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. Never install the rim with the valve stem to the inside of the vehicle. Always ensure that all nuts are torqued to ...

143 MAINTENANCE AND LUBRICATION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service. Bolt Size Torque Specification Front 3/8 ″ 30-35 ft. lbs. (40-47 Nm) Rear 3/8 ″ 30-35 ft. lbs. (40-47 Nm)

144 MAINTENANCE AND LUBRICATION Boot Inspection Before Operating Inspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, see your Polaris dealer for service or replacement. Good Boot After Operating Inspect the boots after operating the vehicle. If a boot is bu...

145 MAINTENANCE AND LUBRICATION Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. NOTE: Do not use any tools that may damage the boot. 2. Slide the free end of the boot two inches toward the center of the vehicle and lift th...

146 ADJUSTMENTS Brakes Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or remo...

147 ADJUSTMENTS Brakes 1. Always keep brake fluid at an adequate level. See page 56. 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.6. ...

148 ADJUSTMENTS 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. Toe Alignment Use the following procedure to check toe alignment. The vehicle...

149 ADJUSTMENTS Toe Alignment 4. Tie an elastic string (2) around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle. 5. Measure the distance between the string in front of the rear tires (...

150 ADJUSTMENTS Chain Tension CAUTION Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Check the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the...

152 ADJUSTMENTS Handlebars If desired, the handlebars can be adjusted for rider preference. WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars, which could result in loss of control and serious inj...

153 ADJUSTMENTS Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the steering post, see your Polaris dealer for service before operating the vehicle. Camber and Caster The c...

154 ADJUSTMENTS Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the front of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Meas...

155 ADJUSTMENTS Front Suspension Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the suspension. 7. Turn the handlebars fully to the left and right.8. With the rider still on the vehicl...

156 ADJUSTMENTS Front Suspension Spring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. WARNING Uneven adjustment may cause poor handling of the ATV, which could result in an accident and serious injury or death. Always adjust both the le...

157 ADJUSTMENTS Front Suspension Spring Preload 1. Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend. 2. Turn the adjusting ring (1) clockwise to increase preload (A). Turn the ring counter-clockwise to decrease preload (B). A B 1

158 ADJUSTMENTS Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the rear of the vehicle by placing a suitable stand under the frame. NOTE: The tires should be barely touching the ground and the suspension should be at full rebound. 4. Measur...

160 ADJUSTMENTS Rear Suspension When the adjuster screw is turned counter-clockwise until it stops, the damping is in the softest position (position #1). Turn the screw clockwise to increase damping. NOTE: Use a flat blade screwdriver to make damping adjustments. Rear Shock Setting Compression Dampi...

161 ADJUSTMENTS Rear Suspension The rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different riding conditions and operator weight. Spring Preload 1. Raise and safely support the rear of the ATV off the ground to allow the suspension to fu...

1 162 ADJUSTMENTS Rear Suspension Compression Damping The compression damping clickers (1) are located on the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments.To set the shock at the softest setting (position #1) turn the screw counter-clockwise until it stops. From ...

163 ADJUSTMENTS Clutch Lever Freeplay 1. Measure clutch lever freeplay between the perch and the lever (A). This distance should be 1/8 ″ - 3/16 ″ (3-4.7 mm). 2. If adjustment is required, slide the clutch perch pivot boot down the clutch cable to access the clutch adjustment screw (B) and lock ring...

164 ADJUSTMENTS Throttle Cable Freeplay WARNING Improper adjustment of throttle cable freeplay can result in loss of control, which could result in serious injury or death. Polaris recommends that this procedure be performed by a Polaris dealer to ensure that it’s done correctly. Mechanically knowle...

165 ADJUSTMENTS Carburetor/Idle RPM If the engine idle speed is not satisfactory, and all other conditions are favorable, the carburetor can be adjusted.1. Warm up the engine by running the vehicle for five minutes, or until operating temperature is reached. 2. Apply the parking brake and place the ...

166 ADJUSTMENTS Carburetor/Idle RPM Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes and temperatures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m...

167 CLEANING AND STORAGE Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. CAUTION High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using m...

168 CLEANING AND STORAGE Washing the Vehicle The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water.1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last. 2. Rinse with clean water frequently.3. Dry sur...

170 CLEANING AND STORAGE Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follow the instructions on the container. Polishing Tips S Avoid the use of automotive products, some of which can scratch the fini...

171 CLEANING AND STORAGE Storage Recommendations CAUTION Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as ...

172 CLEANING AND STORAGE Storage Recommendations Oil and Filter Warm the engine and change the oil and filter. See page 105. Air Filter / Air Box Inspect and clean or replace the pre-cleaner and air filter. Clean the air box and drain the sediment tube. Breather Filter Inspect and clean or replace t...

173 CLEANING AND STORAGE Storage Recommendations Fog the Engine 1. Start the engine and allow it to warm up. Turn engine off.2. Unlatch and remove the seat.3. Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor.4. Start the engine and spray Polaris fogging oil or a co...

174 CLEANING AND STORAGE Storage Recommendations Inspect and Lubricate Inspect all cables and lubricate. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Engine Anti...

175 CLEANING AND STORAGE Transporting the ATV Follow these procedures when transporting the vehicle.1. Turn off the engine and remove the key to prevent loss during transporting. 2. Turn the fuel valve off.3. Be sure the fuel cap, oil cap and seat are installed correctly. 4. Always tie the frame of ...

176 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 Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12.8 VDC Loose battery connections ...

177 TROUBLESHOOTING Engine Turns Over, Fails to Start Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Clogged fuel valve Inspect and clean or replace Water is present in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old, poor or non-reco...

178 TROUBLESHOOTING Engine Pings or Knocks Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Backfires Possible Cause Solution Weak, f...

179 TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Fouled or defective spark plug Inspect, clean and/or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ig...

180 TROUBLESHOOTING Engine Runs Irregularly, Stalls or Misfires Possible Lean Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Low octane fuel Replace with recommended fuel Old, poor or non-recommended fuel Replace with recommended fuel Clogged fuel valv...

181 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...

182 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Clogged, dirty or wet air filter Inspect and clean or replace Electronic throttle control (ETC) malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and cor...

183 POLARIS PRODUCTS Part # Description Part # Description Engine Lubricant Coolant 2874414 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2871323 60/40 Coolant (gal.) 2874415 PS-4 Oil (gal.) 2871534 60/40 Coolant (qt.) Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season (3 o...

184 SPECIFICATIONS OUTLAW Gross Vehicle Weight 645 lbs./292 kg Pilot Jet 37.5 Fuel Capacity 3.25 gal./12.3 l Main Jet 145 Overall Length 71.5 in./182 cm Needle Jet O-0 Overall Width 47.5 in./121 cm Jet Needle 6GL68-40-#2 Overall Height 45 in./114 cm Alternator Output 200 w @ 3000 RPM Wheelbase 51 in...

185 SPECIFICATIONS OUTLAW Driving System Type Rear Two-Wheel Drive Tire Size/Pressure - Front 21 x 7R10 / 5 psi Shift Type 5-Speed Manual Shift Tire Size/Pressure - Rear 20 x 10R9 / 5 psi Primary Ratio 2.880 Front Brake Hydraulic Disc Gear Ratio - 1st 2.429 Rear Brake Hydraulic Disc Gear Ratio - 2nd...

186 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...

187 WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This ...

189 WARRANTY HOW TO OBTAIN WARRANTY SERVICE If your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANSPORTATION TO AND F...

190 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL- LETIN 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 expo...

191 WARRANTY Exported Vehicles How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs...

192 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...

195 MAINTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.

198 INDEX A Age Restrictions 14 . . . . . . . . . . . . Air Filter Systems 114-115 . . . . . . . B Battery 134 . . . . . . . . . . . . . . . . . . Battery Charging, Sealed Battery 137-139 . . . . . Battery Installation 136 . . . . . . . . . Battery Removal 135 . . . . . . . . . . . Battery Storage 1...