Polaris Offroad Vehicle - Manuals

The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family--- the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have c...

CONTENTS UNDERSTANDING WARNINGS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY WARNING AND OPERATION DECALS 3-13 . . . . . . . . . . . DAILY PRE-RIDE INSPECTION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION WARNINGS 15-33 . . . . . . . . . . . . . . . . . . . . ....

1 UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for any- one under 18 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various ...

2 UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety i...

3 SAFETY WARNING AND OPERATION DECALS NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes il- legible or comes off, contact your Polaris dealer for a replacement. Any safety de- cal needing...

9 SAFETY WARNING AND OPERATION DECALS WARNING LOAD DISTRIBUTION WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating char- acteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure ...

10 SAFETY WARNING AND OPERATION DECALS WARNING RACK LOAD WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow...

11 SAFETY WARNING AND OPERATION DECALS 8 ATTENTION D OPERATION OF THIS VEHICLE WITHOUT THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE. D CLEAN AIR FILTER OFTEN, MORE FRE- QUENT CLEANING REQUIRED IN DUSTY CONDITIONS. D L i utilisation de ce véhicule sous l i élément filtre endommage sévèrement le...

12 SAFETY WARNING AND OPERATION DECALS 9 10 DO NOT ATTEMPT ENGINE ORCLUTCH MODIFICATION. DOING SOCAN CAUSE IMBALANCE AND/OREXCESSIVE ENGINE RPM.EXCESSIVE ENGINE RPM CAN CAUSEPART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH.DO NOT MODIFY ENGINE OR CLUTCH. 9 10 BELT -- CLUTCH GUARD COVERS MOV...

14 DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result.Always inspect your ATV before ri...

15 OPERATION WARNINGS WARNING 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 dif- ferent types of terrain.HOW TO AVOID THE H...

34 VEHICLE IDENTIFICATION NUMBERS 2 On recoil housing 1 VIN on the lower left side of the frame tube Important: Record these numbers from your ATV in the spaces provided. 1. Frame VIN 2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Recor...

35 CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re- verse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle ...

36 CONTROL AND PARTS FUNCTIONS Light Switches and Indicator Lights Switches Each Polaris ATV has a main switch. It is located on the right hand side of the ma- chine and operated with a key.The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also ...

38 CONTROL AND PARTS FUNCTIONS Engine Throttle and Choke Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle le- ver. The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electron...

39 CONTROL AND PARTS FUNCTIONS Throttle Control/Brakes Throttle Control Lever Stop The throttle control lever incorporates an adjustable stop. This can be ad- justed to limit the amount of throttle opening by loosening the screw (A) and sliding the stop to a desired setting. Then tighten screw. Fron...

40 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever two or three times and hold it. 2. Rotate the park brake lock into the notches on the master cylinder body. Release the brake lever. 3. To release the parking brake lock, squeeze the brake lev...

41 CONTROL AND PARTS FUNCTIONS Auxiliary Mechanical Brake Your Polaris ATV has an auxiliary mechanical brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the hydraulic brake system, especially if t...

42 CONTROL AND PARTS FUNCTIONS 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...

43 CONTROL AND PARTS FUNCTIONS Demand 4 Drive (Found on models with All Wheel Drive) AWD Button AWD Button Out “Off” AWD Button in “On” AWD Indicator Light Exclusive Demand 4 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system whi...

44 CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 4 Drive and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward ag...

45 CONTROL AND PARTS FUNCTIONS Engine Cooling SystemCoolant Level The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.The engine coolant level is controlled or maintained by the recovery sys- tem. Th...

46 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level InspectionNOTE: This procedure is only re- quired if the cooling system has been drained for maintenance and/or re- pair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant...

48 CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System 1 2 The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual Supplement for tank capacity. Use either leaded or unleaded gas- oline with a minimum pump octane number of 87 R+ M/2 octane.On models wit...

50 CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis- cosity oil designed to provide the ultimate in lubrication pe...

51 CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) 4. Place a drain pan beneath the oil tank and remove the drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. 5. Allow oil to drain completely.6. Install a new sealing washer...

52 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil. CAUTION: Eng...

54 CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained....

55 STARTING THE ENGINE Procedure for Starting a Cold Engine 1. Place the transmission in neutral and push the vehicle to a level surface.2. Lock the parking brake.3. Turn the fuel tank valve to ON.4. Sit on the vehicle. “HALF” “FULL” “OFF” Choke Lever Side View 5. Move the choke lever to the FULL po...

56 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 per- f...

57 VEHICLE BREAK-IN PERIOD 4 Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of op- eration, 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. Careful treatment of ...

58 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 important piece of protective gear for safe ridin...

59 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 operating over rough or hilly terrain, reduce speed and car- go to maintain stable driving conditions....

60 CARGO WEIGHT DISTRIBUTION 2/3 of Load on Rear Rack 1/3 of Load on Front Rack WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load af- fects the vehicle’s turning, stopping distance and sta...

62 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. Release the parking brake.5. Slowly depress the throttl...

63 RIDING 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...

64 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading...

65 RIDING Traveling Uphill 25 _ Maximum Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills.2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to take emergency act...

66 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 k...

67 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 ...

68 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. Stop and lock the parking brake while maintaining body weight uphill.2. Leave ...

69 RIDING Crossing Streams Your Polaris ATV can operate through water up to 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.4. A...

70 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. WARNING Hidden or unseen hazards on the trail can be dangerous.Personal injury...

71 RIDING Backing Up Backing Up 1. Whenever backing up, 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.6. Never activate override button while throttl...

72 RIDING Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off.2. Place the transmission in gear.3. Set the parking brake.4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 5. Shut off fu...

73 BATTERY Battery CAUTION Whenever removing the battery, discon- nect the negative (black) cable first. When reinstalling the battery, connect the nega- tive (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often....

74 BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and battery 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. Lift t...

75 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or eleme...

76 MAINTENANCE Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows:1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the en- gine. Purge accumulated carbon from the system by mome...

78 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 fo...

79 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important compo- nents are explained in the following chartMaintenance intervals are based upon average ri...

82 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil (2-Cycle) Polaris Injection Oil Fill oil tank. See page 48. As needed, when refueling 2.Engine OIl (4-Cycle) Polaris Pre- mium 4 Syn- thetic 0W40 Add to proper level on dipstick. See page 50. Check level dai- l...

85 MAINTENANCE Lubrication Recommendations 4WD 17. Steering Post Bushings 25. Tie Rod End 25. Tie Rod End 13. Ball Joint 14. Front A-Arm Pivot Shaft Lower Upper 11. 4 O’clock position 11. Demand 4 Hubs 17. Steering Post Bushings 25. Tie Rod Ends 13. Ball Joint 14. Front A-Arm Pivot Shaft Lower Upper...

88 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs.50 Hrs.75 Hrs. 100 Hrs.

90 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Model Item Specification Front Spindle Nut(s) 40 Ft. Lbs. 2 X 4 Front Wheel Nuts 15 Ft. Lbs. 2 X 4 Rear Axle Nut(s) 80 Ft. ...

91 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 Cam

92 MAINTENANCE Optional Suspension Springs Although your Polaris ATV suspension has the capability of providing you with the best ride possible, the following accessory springs are available to better suit your individual riding preference. NOTE: Optional springs may be a different color than standa...

95 MAINTENANCE Air Cleaner Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Dual Stage Air Cleaner The Polaris ATV is equipped with a dual stage engine air filtration system. The primary pre-cleaner foam boot is designed to remove the majority of dust particles before they reach the secondary dry fi...

96 MAINTENANCE Air Cleaner Trail Blazer, Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Secondary (Main) Filter Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid...

97 MAINTENANCE Air Filter Service Magnum 2 x 4, Magnum 4 x 4 It is recommended that the air filter be inspected weekly and replaced if dirty. When riding in extremely dusty conditions replacement will be required more often.1. Lift up on the rear of the seat.2. Pull the seat back and free of the tab...

98 MAINTENANCE Primary Pre-Filter Service Magnum 2x4 and 4x4 The pre filter should be cleaned before each ride, using the following procedure. 1. Remove pre-filter element. Note position of duct support wire. It must be properly posi- tioned before reinstalling pre- filter. 2. Clean the element with...

102 MAINTENANCE CAUTION: Operation of your ATV without a breather filter can cause engine dam- age. Breather Filter and Hoses Scrambler 500 WARNING: Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns.1. Remove heat ...

103 MAINTENANCE Breather Filter and Hose Sportsman 500, Xplorer 500 1. Remove seat and airbox lid.2. Locate foam breather filter which is in the front left corner of airbox covering the engine breather hose fitting hole on the front inside of the airbox. 3. Pull filter out and blow off with compress...

104 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. Toe Alignment You...

105 MAINTENANCE Front Brake The front brakes are hydraulic disc type brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and re- quire no adjustment.The following checks are recommended to keep the brake system in good operat- ing condition...

106 MAINTENANCE Rear and Auxiliary Mechanical Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake sys- tem is self adjusting and requires no maintenance other than periodic checks of the pads for w...

107 MAINTENANCE Auxiliary Brake Adjustment (Cont.) Polaris ATVs have two different types of auxiliary brake adjustment. Consult your owner’s manual supplement to determine what type your machine has and adjust accordingly.1. Type I: If adjustment is neces- sary turn adjuster bolt (A) clock- wise unt...

108 MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor ad- justments which are found in the own- er’s manual supplement. 2. Remove electronic throttle control (ETC) cover. 3. Loosen throttle cable jam nut and turn adjuster in ...

110 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 reservoir and supply line have been completely run out of oil. In these cases, loos...

111 MAINTENANCE Engine Choke Adjustment 2 Cycle Engines With the dash mounted choke control toggle flipped to 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 s...

112 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 the vehicle approximately five minutes. 2. Place the transmission in ...

113 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satis- factory, and all other conditions are favorable, the carburetor can be ad- justed as follows:1. Warm up the engine by running the vehicle approximately five minutes. 2. Place the transmission...

114 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. Immedia...

115 MAINTENANCE Transmission Lubrication Transmission Dipstick The transmission dipstick is located on the right side of the machine.The transmission lubricant level should be checked monthly or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on...

116 MAINTENANCE Front Gearcase Lubrication Sport 500, Xplorer 500, Scrambler 400 Fill plug Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the machine.The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever come...

117 MAINTENANCE Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil should be added or changed as necessary. The oil should be changed annually, especially be- fore off season storage. If the ma- chine is used in wet conditions the oil should be ch...

118 MAINTENANCE Wheel Removal Front or Rear Wheel Removal Procedure 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 by placing a suitable stand under the footrest frame as shown. 4. Remove the wheel nu...

119 MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability.When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect ATV handling. Tir...

120 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION: Never wash the chain with a high pressure washer or gasoline. Da...

121 MAINTENANCE Adjustment Procedure (cont.) 5. Tighten eccentric clamp bolts to 45 ft. lbs. (6.21 kg/m). Check chain tension. Gen II and III Models 1. Remove cotter pin and washer connecting brake pedal linkage to caliper actu- ating arm. Remove linkage from arm. 2. Remove right front fender mud fl...

122 MAINTENANCE Rear Drive Chain Slack Adjustment CAUTION: 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. Chain tension must be inspected with the swing arm in the position shown in illustrati...

123 MAINTENANCE Headlight Lamp Replacement WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service...

124 MAINTENANCE Headlight Lamp Replacement Trail Blazer, Sport WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAU...

126 MAINTENANCE Headlight Adjustment 10. Carefully unplug the socket from the lamp. Remove the panel and set it aside.11. Replace the oil reservoir cap.12. Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 13. Disengage the wire bail hold...

128 MAINTENANCE Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also a...

129 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work thelamp may need to be replaced. 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recom- mended lamp. 3. Test the t...

130 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 precautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be ...

131 MAINTENANCE Storage (Cont.) 7. Drain the recoil housing.8. Block the ATV so all tires are sus- pended off the ground. 9. Add Polaris Premium Storage Stabilizer to the fuel tank. 10. Cover the ATV with a canvas cover. Do not use plastic or coated materials since they do not allow ventilation of t...

132 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START Stop Switch Off No Fuel Water i...

133 PAINT CODES Model Item Color Raw Material No. PPG Ditzler No. Springs Fire Red 8520149 7060 1998 Trail Boss Rims Bright White 8520153 2185 Trail Boss Rack Fire Red 8520149 72060 Springs Black 8520147 9440 1998 Magnum 2x4 Rims Brushed Alu- minum N/A N/A Rack Black 8520147 9440 1998 Springs Fire R...

135 ACCESSORIES Trail Blazer Trail Boss Sport Xpress 300 14 Gallon Sprayer N/A 2871087 N/A 2871087 Boom Mounting Kit N/A 2871340 N/A 2871340 42 ″ Spray Boom N/A 2871088 N/A 2871088 123 ″ Spray Boom N/A 2871089 N/A 2871089 Seeder/Spreader, Elec. N/A 2871219 N/A 2871219 Speedometer 2871275 2871275 287...

144 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-- 5078, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polar- is also gives a one year limited warran...

145 WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defec- tive materials, or components or produc...

INDEX 146 Engine Cooling System 45-47 . . . . . . . . . . Accessories 135-143 . . . . . . . . . . . . . . . . . Air Box Drain 98 . . . . . . . . . . . . . . . . . . . . . Air Cleaner 95-101 . . . . . . . . . . . . . . . . . . Air Filter Service, Magnum 97 . . . . . . . . . Air Filter Service, Sport,...

The Polaris Preferred Registered Owners (PRO) Family Your Owners Program As the owner of a new Polaris vehicle, you are entitled to a FREE two- year mem- bership in the Polaris PRO Family--- the Preferred Registered Owners Family. It’s an owners program for Polaris owners like you, people who have c...

CONTENTS UNDERSTANDING WARNINGS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY WARNING AND OPERATION DECALS 3-13 . . . . . . . . . . . DAILY PRE-RIDE INSPECTION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION WARNINGS 15-33 . . . . . . . . . . . . . . . . . . . . ....

1 UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY; not a toy. Operation is prohibited for any- one under 18 years of age. READ AND UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE OPERATION. KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING! Read this manual thoroughly referring to the various ...

2 UNDERSTANDING WARNINGS SAFETY ALERT The following precautionary signal words are used throughout this manual to con- vey the following messages: This is the safety alert symbol. When you see this symbol on your machine or in this manual, be alert to the potential for personal injury. Your safety i...

3 SAFETY WARNING AND OPERATION DECALS NOTE: Warning decals have been placed on the vehicle for your protection. Read and follow the instructions on each decal carefully. In the event any decal becomes il- legible or comes off, contact your Polaris dealer for a replacement. Any safety de- cal needing...

9 SAFETY WARNING AND OPERATION DECALS WARNING LOAD DISTRIBUTION WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating char- acteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure ...

10 SAFETY WARNING AND OPERATION DECALS WARNING RACK LOAD WARNINGS Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load effects the vehicles turning, stopping distance and stability. Failure to follow...

11 SAFETY WARNING AND OPERATION DECALS 8 ATTENTION D OPERATION OF THIS VEHICLE WITHOUT THE FILTER ELEMENT WILL SEVERELY DAMAGE THE ENGINE. D CLEAN AIR FILTER OFTEN, MORE FRE- QUENT CLEANING REQUIRED IN DUSTY CONDITIONS. D L i utilisation de ce véhicule sous l i élément filtre endommage sévèrement le...

12 SAFETY WARNING AND OPERATION DECALS 9 10 DO NOT ATTEMPT ENGINE ORCLUTCH MODIFICATION. DOING SOCAN CAUSE IMBALANCE AND/OREXCESSIVE ENGINE RPM.EXCESSIVE ENGINE RPM CAN CAUSEPART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH.DO NOT MODIFY ENGINE OR CLUTCH. 9 10 BELT -- CLUTCH GUARD COVERS MOV...

14 DAILY PRE-RIDE INSPECTION Inspect your ATV each time before riding to ensure it is in proper working or- der. If proper inspection is not done, severe injury or death could result. WARNING If a proper inspection is not performed serious injury or death can result.Always inspect your ATV before ri...

15 OPERATION WARNINGS WARNING 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 dif- ferent types of terrain.HOW TO AVOID THE H...

34 VEHICLE IDENTIFICATION NUMBERS 2 On recoil housing 1 VIN on the lower left side of the frame tube Important: Record these numbers from your ATV in the spaces provided. 1. Frame VIN 2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Recor...

35 CONTROL AND PARTS FUNCTIONS Engine Electrical Switches 1. Override Switch (Reverse Speed Limiter) - This vehicle is equipped with a re- verse speed limiter system. To obtain additional power while backing up, depress the override button. WARNING: Never activate the override button while throttle ...

36 CONTROL AND PARTS FUNCTIONS Light Switches and Indicator Lights Switches Each Polaris ATV has a main switch. It is located on the right hand side of the ma- chine and operated with a key.The light switch is located on the left hand handlebar. In addition to turning the lights on and off, it also ...

38 CONTROL AND PARTS FUNCTIONS Engine Throttle and Choke Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle le- ver. The throttle lever is spring loaded and engine speed returns to idle when the lever is released. This vehicle is equipped with a Polaris Electron...

39 CONTROL AND PARTS FUNCTIONS Throttle Control/Brakes Throttle Control Lever Stop The throttle control lever incorporates an adjustable stop. This can be ad- justed to limit the amount of throttle opening by loosening the screw (A) and sliding the stop to a desired setting. Then tighten screw. Fron...

40 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake 1. Squeeze the left hand brake lever two or three times and hold it. 2. Rotate the park brake lock into the notches on the master cylinder body. Release the brake lever. 3. To release the parking brake lock, squeeze the brake lev...

41 CONTROL AND PARTS FUNCTIONS Auxiliary Mechanical Brake Your Polaris ATV has an auxiliary mechanical brake provided as a safety feature. It is located on the inside of the right floor board and is operated by the right foot. It is intended as a backup to the hydraulic brake system, especially if t...

42 CONTROL AND PARTS FUNCTIONS 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...

43 CONTROL AND PARTS FUNCTIONS Demand 4 Drive (Found on models with All Wheel Drive) AWD Button AWD Button Out “Off” AWD Button in “On” AWD Indicator Light Exclusive Demand 4 Drive System (All Wheel Drive) This Polaris AWD is equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system whi...

44 CONTROL AND PARTS FUNCTIONS Disengaging Wheel Hubs When backing uphill while in Demand 4 Drive and then going forward downhill, one or both hubs may remain engaged. If one or both hubs remain engaged they can be disengaged by stopping, shifting to and moving in reverse. Then proceed in forward ag...

45 CONTROL AND PARTS FUNCTIONS Engine Cooling SystemCoolant Level The recovery bottle, located on the left side of the machine, must be maintained between the minimum and maximum levels indicated on the recovery bottle.The engine coolant level is controlled or maintained by the recovery sys- tem. Th...

46 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level InspectionNOTE: This procedure is only re- quired if the cooling system has been drained for maintenance and/or re- pair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant...

48 CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System 1 2 The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual Supplement for tank capacity. Use either leaded or unleaded gas- oline with a minimum pump octane number of 87 R+ M/2 octane.On models wit...

50 CONTROL AND PARTS FUNCTIONS 4 Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4 cycle engines. It is a fully synthetic, high performance, multi-vis- cosity oil designed to provide the ultimate in lubrication pe...

51 CONTROL AND PARTS FUNCTIONS Oil and Filter Change (Cont.) 4. Place a drain pan beneath the oil tank and remove the drain plug. CAUTION: Oil may be hot. Do not allow hot oil to come into contact with skin as serious burns may result. 5. Allow oil to drain completely.6. Install a new sealing washer...

52 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our products and highly recommends their use. The only oils recommended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil. CAUTION: Eng...

54 CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Remove the screw with a 10mm wrench. Reinstall screw once housing has been drained....

55 STARTING THE ENGINE Procedure for Starting a Cold Engine 1. Place the transmission in neutral and push the vehicle to a level surface.2. Lock the parking brake.3. Turn the fuel tank valve to ON.4. Sit on the vehicle. “HALF” “FULL” “OFF” Choke Lever Side View 5. Move the choke lever to the FULL po...

56 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 per- f...

57 VEHICLE BREAK-IN PERIOD 4 Cycle Engines The break in period for your new Polaris ATV is defined as the first ten hours of op- eration, 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. Careful treatment of ...

58 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 important piece of protective gear for safe ridin...

59 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 operating over rough or hilly terrain, reduce speed and car- go to maintain stable driving conditions....

60 CARGO WEIGHT DISTRIBUTION 2/3 of Load on Rear Rack 1/3 of Load on Front Rack WARNING Correct loading of this vehicle is necessary to maintain proper stability and operating characteristics. Overloading or incorrect positioning of the load af- fects the vehicle’s turning, stopping distance and sta...

62 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. Release the parking brake.5. Slowly depress the throttl...

63 RIDING 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...

64 RIDING Riding On Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during cold freezing weather, special attention must be paid to prevent vehicle turnover. Always: 1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading...

65 RIDING Traveling Uphill 25 _ Maximum Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills.2. Keep both feet on the footrests.3. Transfer your weight forward.4. Proceed at a steady rate of speed and throttle opening.5. Remain alert and be prepared to take emergency act...

66 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 k...

67 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 ...

68 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. Stop and lock the parking brake while maintaining body weight uphill.2. Leave ...

69 RIDING Crossing Streams Your Polaris ATV can operate through water up to 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.4. A...

70 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. WARNING Hidden or unseen hazards on the trail can be dangerous.Personal injury...

71 RIDING Backing Up Backing Up 1. Whenever backing up, 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.6. Never activate override button while throttl...

72 RIDING Parking on an Incline Whenever the Vehicle is Parked 1. Turn the engine off.2. Place the transmission in gear.3. Set the parking brake.4. Avoid parking on an incline. If it is necessary to park on an incline, always block the rear wheels on the down hill side as shown above. 5. Shut off fu...

73 BATTERY Battery CAUTION Whenever removing the battery, discon- nect the negative (black) cable first. When reinstalling the battery, connect the nega- tive (black) cable last. Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often....

74 BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and battery 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. Lift t...

75 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED!U.S. Federal law prohibits the following acts or the causing thereof:(1) The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or eleme...

76 MAINTENANCE Spark Arrestor The exhaust pipe must be periodically purged of accumulated carbon as follows:1. Remove the clean out plugs located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the en- gine. Purge accumulated carbon from the system by mome...

78 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 fo...

79 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication intervals of important compo- nents are explained in the following chartMaintenance intervals are based upon average ri...

82 MAINTENANCE Lubrication Recommendations Item Lube Rec. Method Frequency* 1. Engine Oil (2-Cycle) Polaris Injection Oil Fill oil tank. See page 48. As needed, when refueling 2.Engine OIl (4-Cycle) Polaris Pre- mium 4 Syn- thetic 0W40 Add to proper level on dipstick. See page 50. Check level dai- l...

85 MAINTENANCE Lubrication Recommendations 4WD 17. Steering Post Bushings 25. Tie Rod End 25. Tie Rod End 13. Ball Joint 14. Front A-Arm Pivot Shaft Lower Upper 11. 4 O’clock position 11. Demand 4 Hubs 17. Steering Post Bushings 25. Tie Rod Ends 13. Ball Joint 14. Front A-Arm Pivot Shaft Lower Upper...

88 MAINTENANCE Periodic Maintenance Record Use the following chart to record periodic maintenance work: Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs. 25 Hrs.50 Hrs.75 Hrs. 100 Hrs.

90 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Axle and Wheel Nut Torque Specifications Model Item Specification Front Spindle Nut(s) 40 Ft. Lbs. 2 X 4 Front Wheel Nuts 15 Ft. Lbs. 2 X 4 Rear Axle Nut(s) 80 Ft. ...

91 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 Cam

92 MAINTENANCE Optional Suspension Springs Although your Polaris ATV suspension has the capability of providing you with the best ride possible, the following accessory springs are available to better suit your individual riding preference. NOTE: Optional springs may be a different color than standa...

95 MAINTENANCE Air Cleaner Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Dual Stage Air Cleaner The Polaris ATV is equipped with a dual stage engine air filtration system. The primary pre-cleaner foam boot is designed to remove the majority of dust particles before they reach the secondary dry fi...

96 MAINTENANCE Air Cleaner Trail Blazer, Trail Boss, Xpress 300, Xplorer 300, Xplorer 400 Secondary (Main) Filter Inspect the secondary filter weekly or after every 50 hours of operation. CAUTION: Never operate the ATV with the filter element removed. Dirt will enter the engine causing serious rapid...

97 MAINTENANCE Air Filter Service Magnum 2 x 4, Magnum 4 x 4 It is recommended that the air filter be inspected weekly and replaced if dirty. When riding in extremely dusty conditions replacement will be required more often.1. Lift up on the rear of the seat.2. Pull the seat back and free of the tab...

98 MAINTENANCE Primary Pre-Filter Service Magnum 2x4 and 4x4 The pre filter should be cleaned before each ride, using the following procedure. 1. Remove pre-filter element. Note position of duct support wire. It must be properly posi- tioned before reinstalling pre- filter. 2. Clean the element with...

102 MAINTENANCE CAUTION: Operation of your ATV without a breather filter can cause engine dam- age. Breather Filter and Hoses Scrambler 500 WARNING: Do not perform this operation immediately after the engine has been run. The exhaust system becomes very hot and can cause severe burns.1. Remove heat ...

103 MAINTENANCE Breather Filter and Hose Sportsman 500, Xplorer 500 1. Remove seat and airbox lid.2. Locate foam breather filter which is in the front left corner of airbox covering the engine breather hose fitting hole on the front inside of the airbox. 3. Pull filter out and blow off with compress...

104 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, have your dealer tighten them before riding your vehicle. Camber and Caster The camber and caster are non-adjustable. Toe Alignment You...

105 MAINTENANCE Front Brake The front brakes are hydraulic disc type brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and re- quire no adjustment.The following checks are recommended to keep the brake system in good operat- ing condition...

106 MAINTENANCE Rear and Auxiliary Mechanical Brake Rear Brake The rear brake is a hydraulic disc type brake which is activated by the same lever which activates the front brake system. The rear brake sys- tem is self adjusting and requires no maintenance other than periodic checks of the pads for w...

107 MAINTENANCE Auxiliary Brake Adjustment (Cont.) Polaris ATVs have two different types of auxiliary brake adjustment. Consult your owner’s manual supplement to determine what type your machine has and adjust accordingly.1. Type I: If adjustment is neces- sary turn adjuster bolt (A) clock- wise unt...

108 MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor ad- justments which are found in the own- er’s manual supplement. 2. Remove electronic throttle control (ETC) cover. 3. Loosen throttle cable jam nut and turn adjuster in ...

110 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 reservoir and supply line have been completely run out of oil. In these cases, loos...

111 MAINTENANCE Engine Choke Adjustment 2 Cycle Engines With the dash mounted choke control toggle flipped to 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 s...

112 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 the vehicle approximately five minutes. 2. Place the transmission in ...

113 MAINTENANCE Carburetor/Engine Idle RPM Adjustment 4-cycle Engines If the engine idle speed is not satis- factory, and all other conditions are favorable, the carburetor can be ad- justed as follows:1. Warm up the engine by running the vehicle approximately five minutes. 2. Place the transmission...

114 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. Immedia...

115 MAINTENANCE Transmission Lubrication Transmission Dipstick The transmission dipstick is located on the right side of the machine.The transmission lubricant level should be checked monthly or 1000 miles (1600 km), whichever comes first. Transmission oil should be changed annually. With the ATV on...

116 MAINTENANCE Front Gearcase Lubrication Sport 500, Xplorer 500, Scrambler 400 Fill plug Front Gearcase Lubrication The front gearcase fill plug is located on the right side of the machine.The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever come...

117 MAINTENANCE Counter Balance Lubrication 400 Engines The counter balance oil should be checked semi-annually and oil should be added or changed as necessary. The oil should be changed annually, especially be- fore off season storage. If the ma- chine is used in wet conditions the oil should be ch...

118 MAINTENANCE Wheel Removal Front or Rear Wheel Removal Procedure 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 by placing a suitable stand under the footrest frame as shown. 4. Remove the wheel nu...

119 MAINTENANCE Tire Inspection CAUTION: Maintain proper tire pressure according to charts below. Improper tire inflation may affect ATV maneuverability.When replacing a tire always use original equipment size and type. CAUTION: The use of non-standard size or type tires may affect ATV handling. Tir...

120 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed permanently greased pins and rollers. However, it is still necessary to lubricate the outer surfaces of the roller. CAUTION: Never wash the chain with a high pressure washer or gasoline. Da...

121 MAINTENANCE Adjustment Procedure (cont.) 5. Tighten eccentric clamp bolts to 45 ft. lbs. (6.21 kg/m). Check chain tension. Gen II and III Models 1. Remove cotter pin and washer connecting brake pedal linkage to caliper actu- ating arm. Remove linkage from arm. 2. Remove right front fender mud fl...

122 MAINTENANCE Rear Drive Chain Slack Adjustment CAUTION: 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. Chain tension must be inspected with the swing arm in the position shown in illustrati...

123 MAINTENANCE Headlight Lamp Replacement WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAUTION: Do not service...

124 MAINTENANCE Headlight Lamp Replacement Trail Blazer, Sport WARNING: Due to the nature of ATVs and where they are ridden, headlight and taillight lenses become dirty. Frequent washing is necessary to maintain light- ing quality. Poor lighting while riding can result in severe injury or death. CAU...

126 MAINTENANCE Headlight Adjustment 10. Carefully unplug the socket from the lamp. Remove the panel and set it aside.11. Replace the oil reservoir cap.12. Stand the panel containing the headlight assembly on end to allow access to the back of the headlight assembly. 13. Disengage the wire bail hold...

128 MAINTENANCE Headlight Housing Replacement 1. Remove Phillips screws from bottom of headlight pod at each front corner. NOTE: To aid in accessing these screws, it may be helpful to turn handlebars to left or right and use a short, stubby screwdriver. Removal of the front rack and cover may also a...

129 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work thelamp may need to be replaced. 1. From the rear of the taillight remove two screws holding lens cover in place and remove lens cover. 2. Remove lamp and replace it with recom- mended lamp. 3. Test the t...

130 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 precautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must be ...

131 MAINTENANCE Storage (Cont.) 7. Drain the recoil housing.8. Block the ATV so all tires are sus- pended off the ground. 9. Add Polaris Premium Storage Stabilizer to the fuel tank. 10. Cover the ATV with a canvas cover. Do not use plastic or coated materials since they do not allow ventilation of t...

132 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for ques- tions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE CRANKS BUT FAILS TO START Stop Switch Off No Fuel Water i...

133 PAINT CODES Model Item Color Raw Material No. PPG Ditzler No. Springs Fire Red 8520149 7060 1998 Trail Boss Rims Bright White 8520153 2185 Trail Boss Rack Fire Red 8520149 72060 Springs Black 8520147 9440 1998 Magnum 2x4 Rims Brushed Alu- minum N/A N/A Rack Black 8520147 9440 1998 Springs Fire R...

135 ACCESSORIES Trail Blazer Trail Boss Sport Xpress 300 14 Gallon Sprayer N/A 2871087 N/A 2871087 Boom Mounting Kit N/A 2871340 N/A 2871340 42 ″ Spray Boom N/A 2871088 N/A 2871088 123 ″ Spray Boom N/A 2871089 N/A 2871089 Seeder/Spreader, Elec. N/A 2871219 N/A 2871219 Speedometer 2871275 2871275 287...

144 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 1225 Highway 169 North, Minneapolis, Minnesota 55441-- 5078, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polar- is also gives a one year limited warran...

145 WARRANTY This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the ATV. The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option, repair or replacement of any defec- tive materials, or components or produc...

INDEX 146 Engine Cooling System 45-47 . . . . . . . . . . Accessories 135-143 . . . . . . . . . . . . . . . . . Air Box Drain 98 . . . . . . . . . . . . . . . . . . . . . Air Cleaner 95-101 . . . . . . . . . . . . . . . . . . Air Filter Service, Magnum 97 . . . . . . . . . Air Filter Service, Sport,...