Polaris Predator 90 - Manuals

Page 2 - WARNING; The engine exhaust from this

WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

Page 3 - We’ve created a web site just for YOU!; Technical tips

1 We’ve created a web site just for YOU! S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out... www.polarisindustries.com/owner

Page 5 - WELCOME; Polaris Recreational and Utility Vehicles; RANGER; Polaris Professional Series Workmobiles

3 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Personal watercraft S Victor...

Page 7 - TABLE OF CONTENTS

5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TABLE OF CONTENTS 5 . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CONTROLS 37 ...

Page 8 - VEHICLE IDENTIFICATION NUMBERS; serial number (2) are important for model identification when

6 VEHICLE IDENTIFICATION NUMBERS The vehicle frame vehicle identification number (VIN)(1) and engine serial number (2) are important for model identification when registering your vehicle, when obtaining insurance, and when ordering replacement parts. If your vehicle is stolen, these numbers are ess...

Page 9 - SAFETY; Operator Safety; vehicle handles differently than other vehicles, such as

7 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. 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...

Page 10 - The following signal words and symbols appear throughout this; CAUTION

8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. 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 ATV or in this manual, alerts ...

Page 11 - Take a training; Serious injury or death can result if you do not follow these

9 SAFETY Operator Safety S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ATV without proper instruction. Take a training course . Beginners should receive training from a certified instructor. Contact an authorized Polaris ATV dealer or ...

Page 13 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications

11 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to...

Page 14 - does not know how to operate the ATV properly in different

12 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDBeginning...

Page 15 - balance and control the ATV, which could cause an accident

13 SAFETY Operator Safety POTENTIAL HAZARDCarrying a passenger on an ATV.WHAT CAN HAPPENCarrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger.HOW TO AVOID THE HAZARDNever carry a passenger...

Page 16 - surfaces may seriously affect the handling and control of the

14 SAFETY Operator Safety POTENTIAL HAZARDOperating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways.WHAT CAN HAPPENATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss ...

Page 17 - including dirt and gravel roads. In many states it’s illegal to

15 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV on public streets, roads or highways.WHAT CAN HAPPENThe ATV could collide with another vehicle.HOW TO AVOID THE HAZARDNever operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal...

Page 18 - risk of a severe head injury or death in the event of an

16 SAFETY Operator Safety POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident.Operating without eye pro...

Page 19 - operator judgment. Reaction time may be slower and operator

17 SAFETY Operator Safety POTENTIAL HAZARDOperating the ATV after consuming alcohol or drugs.WHAT CAN HAPPENConsumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.Consuming alcohol and/or drugs b...

Page 21 - schedules described in the owner’s manual.

19 SAFETY Operator Safety POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure it’s in ...

Page 22 - terrain. Always be alert to changing terrain conditions.

20 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating the ATV on unfamiliar terrain.WHAT CAN HAPPENUnfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.HOW TO AVOID THE HAZARDTravel slowly and use extra caution when...

Page 23 - cause loss of traction or loss of control, which could result in an

21 SAFETY Operator Safety POTENTIAL HAZARDFailure to use extra caution when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENOperating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overtur...

Page 24 - abilities. Never operate the ATV on hills steeper than 25

22 SAFETY Operator Safety POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds before atte...

Page 25 - sharp drop, or another vehicle or person could be on the other

23 SAFETY Operator Safety POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully before asc...

Page 26 - described in the owner’s manual.

24 SAFETY Operator Safety POTENTIAL HAZARDTraveling downhill improperly.WHAT CAN HAPPENImproperly descending a hill could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for traveling down hills as described in the owner’s manual. NOTE: A special technique is...

Page 27 - mastered the turning technique (on level ground) as described in

25 SAFETY Operator Safety POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning technique ...

Page 28 - improperly dismounting while

26 SAFETY Operator Safety POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the single leve...

Page 29 - trees when possible. If unavoidable, use extreme caution and

27 SAFETY Operator Safety POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fallen trees...

Page 32 - confident that the ice is thick enough and sound enough to

30 SAFETY Operator Safety POTENTIAL HAZARDOverloading the ATV or carrying/towing cargo improperly.WHAT CAN HAPPENOverloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV....

Page 34 - Safety Decals and Locations; Warning decals have been placed on the ATV for your protection.; Trail Blazer models; Drum shift models

32 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by ...

Page 35 - See your Owner’s Manual Supplement for specifications.

33 SAFETY Safety Decals and Locations See your Owner’s Manual Supplement for specifications. IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. T IRE PRESSURE (PSI): FRONT ___ REAR ___ M AXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE...

Page 36 - ATTENTION; Under Seat; NO STEP; On models with racks

34 SAFETY Safety Decals and Locations ATTENTION D Operation of this vehicle without the filter element will severely damage the engine. D Clean air filter often, more frequent cleaning required in dusty conditions Under Seat Moving parts hazard under belt-clutch guard. To prevent serious injury, do ...

Page 37 - Your ATV will not have all of the decals shown on this page.

35 SAFETY Safety Decals and Locations ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY: POLARIS IND DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS ...

Page 38 - Safe Riding Gear

36 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...

Page 39 - CONTROLS; Electrical Switches; the override switch while the throttle is open.; Leaving the keys in the ignition can lead to unauthorized use of

37 CONTROLS Electrical Switches Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. WARNING Override Switch (1) (Reverse Speed Limiter) - This vehicle is equipped wit...

Page 40 - Throttle Lever

38 CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded. Engine speed returns to idle when the lever is released.This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduc...

Page 41 - Light Switches; designed for and must be used for; After opening a bottle of brake fluid, always discard any unused

39 CONTROLS Light Switches The light switch is located on the left handlebar (1). It’s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI-LO beams. NOTE: The lights won’t work unless the key is in the “on” position and the shut-off switch is in the “...

Page 42 - Brake Lever; Operating the ATV with a spongy brake lever can result in

40 CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever.Always test brake lever travel and master cylinder fluid level before ridin...

Page 43 - Parking Brake; Setting the Parking Brake; Important Safeguards; Operating the ATV while the parking brake is engaged could

41 CONTROLS Parking Brake Setting the Parking Brake 1. Squeeze and release the brake lever (1) two or three times, then squeeze and hold. 2. Push the park brake lock (2) forward to engage the brake. Release the brake lever. 3. To release the parking brake lock, squeeze and release the brake lever. I...

Page 44 - Auxiliary Brake; reduce; Aggressively applying the rear brake when backing down a hill may

42 CONTROLS Auxiliary Brake The auxiliary brake (1), is located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.If the rear wheels slide while using the auxiliary brake, r...

Page 45 - Choke

43 CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 59 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side of the vehicle, either below the fender or on the side panel. It has thr...

Page 46 - Fuel Safety

44 CONTROLS Fuel Safety Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever 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 or near the ...

Page 47 - Models with 2-cycle engines have; Mixing brands or using a non-recommended oil may cause serious

45 CONTROLS Oil Injection Tank - 2-Cycle Models Models with 2-cycle engines have oil injection. The oil injection tank filler cap (1) is located on the front of the vehicle. Tank capacity is two quarts (1.9 l.). Mixing brands or using a non-recommended oil may cause serious engine damage. We recomme...

Page 48 - Automatic Transmission Gear Selector; is located on the right side of the; Belt Life; Shifting gears with the engine speed above idle or while the

46 CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle. Shift patterns vary, depending on your model.H: High Gear N: Neutral L: Low Gear R: Reverse P: Park Whenever the ATV is left unattended, always place the transmission in g...

Page 49 - Recoil Starter; Extending the starter rope too far will cause damage to the recoil

47 CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped with automatic decompressors. This ...

Page 50 - FEATURES; Engaging Wheel Hubs; Switching to AWD while the rear wheels are spinning may cause

48 FEATURES All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system that’s activated by a switch (1) on the right handlebar. When the switch is off, the ATV is in 2 wheel drive at all times. When the switch is on, the ATV is ...

Page 51 - Disengaging Wheel Hubs; to one side, it’s likely that one front hub is engaged . If both hubs are; Operating with only one front hub engaged could result in loss of

49 FEATURES All Wheel Drive (AWD) System Disengaging Wheel Hubs Although the hubs normally disengage when operating in reverse, one or both hubs may occasionally remain engaged. If the handlebars pull to one side, it’s likely that one front hub is engaged . If both hubs are engaged, steering effort ...

Page 52 - Indicator Lights

50 FEATURES Indicator Lights The configuration of the indicator lights differs with individual models. Not every model is equipped with all of the lights, and the lights on some models appear in the speedometer. The information in your owner’s manual supplement and on this page will help you identif...

Page 53 - Instrument Cluster; speed from the right front wheel. The instrument cluster measures; Washing the ATV with a high pressure washer may cause water to

51 FEATURES Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s speed to appro...

Page 54 - Rider Information Center

52 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the lower portion of the instrument cluster.1. Gear Indicator - As the shift lever is moved, this will indicate the gear the machine is in:H = High RangeL = Low RangeN = NeutralR = ReverseP = ParkE or ...

Page 55 - mode

53 FEATURES Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - Programmable service intervalThe reverse override button on the left handlebar is also the mode button . NOTE: If using th...

Page 56 - Mode 4 - Programmable Service Interval; OFF

54 FEATURES Instrument Cluster Rider Information Center Mode 4 - Programmable Service Interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is turned off. ...

Page 57 - Diagnostic Mode

55 FEATURES Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.To enter the diagnostics mode:1. Turn the key switch off and wait 20 seconds. 2. Set the park brake and shift th...

Page 58 - OPERATION; The first tank of fuel must be pre-mixed according to the following; high speeds for extended periods during the first three hours of

56 OPERATION 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 fuel. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine will result in m...

Page 60 - working condition before each use.; Item/Inspection Procedure; that axle nuts are secured by cotter pins.; If a proper inspection is not done before each use, severe injury or

58 OPERATION Pre-Ride Inspection Use the following checklist to verify that your vehicle is in proper working condition before each use. Item/Inspection Procedure 1. Tires - Check condition and pressures.2. Fuel and oil tanks - Fill both tanks to their proper levels.3. All brakes - Check operation, ...

Page 61 - Starting the Engine; Starting a Cold Engine; Engine exhaust contains poisonous carbon monoxide and can; damage. Allow the engine to warm up for several minutes before

59 OPERATION Starting the Engine Starting a Cold Engine 1. Place the transmission in neutral and lock the parking brake. 2. Turn the fuel tank valve on.3. Sit on the vehicle.4. Pull the choke knob out until it stops (1). NOTE: The variable choke is fully on when the knob is pulled completely out. Th...

Page 62 - Starting a Warm Engine

60 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in neutral. 2. Lock the parking brake, turn the fuel tank ...

Page 63 - Hauling Cargo; Your ATV has been designed to carry or tow a certain amount of load.; Maximum Towing Capacities; Refer to your owner’s manual supplement for model specific towing; Use low forward gear when hauling or towing heavy cargo to extend

61 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the weights specified in your owner’s manual supplement.Cargo weight should be evenly distributed (...

Page 65 - Driving Safely; Driving Procedures; Sit upright with both feet on the footrests and both hands on the

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

Page 66 - Making Turns; Some Polaris ATVs are equipped with a solid rear axle, which drives; overturn and lead to serious injury. Avoid turning at sharp angles.

64 OPERATION Driving Safely Making Turns Some Polaris ATVs are equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip tra...

Page 67 - Driving on Slippery Surfaces; quick, sharp turns which can cause skids.; Severe damage to drive train may occur if the AWD is engaged; Failure to exercise care when operating on slippery surfaces can

65 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...

Page 68 - Driving Uphill; If all forward speed is lost:; terrain. Improper procedure could cause loss of control or

66 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 footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening. 6. Remain...

Page 69 - Sidehilling; while keeping your feet on the footrests.; as outlined in the owner’s manual.

67 OPERATION Driving Safely Sidehilling Sidehilling can be a dangerous type of driving and should be avoided if at all possible. If you do enter into a situation where sidehilling is necessary, follow these precautions:1. Slow down.2. Lean into the hill, transferring your upper body weight toward th...

Page 70 - Driving Downhill; slightly; Excessive speed can cause loss of control and lead to serious

68 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. Apply the brakes slightly to aid in slowing, using the single brake lever. NOTE: Familiarize yourself with...

Page 71 - Turning Around on a Hill; slowly; Improper hill climbing procedures could cause loss of control or

69 OPERATION Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! One maneuver that can be used when it’s necessary to turn around while climbing a hill is the K-turn:1. Stop and lock the parking brake while keeping body weight uphill.2. L...

Page 72 - Driving Through Water; critical; Major engine damage can result if the vehicle is not thoroughly

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

Page 73 - Driving Over Obstacles; Be constantly alert for hazards such as logs, rocks and low hanging; Severe injury or death can result if your vehicle comes in contact

71 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. Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. Not all ...

Page 74 - Driving in Reverse; lightly; Failure to use caution when operating in reverse can result in

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

Page 75 - Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow

73 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.1. Place the transmission in gear.2. Set the parking brake.3. Always block the rear wheels on the downhill side. See illustration. 4. Shut o...

Page 76 - USFS Approved Spark Arrestor; Exhaust system components are very hot during and after use of

74 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...

Page 77 - MAINTENANCE AND LUBRICATION; Accessories; Maintenance Chart Key

75 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. Accessory outlets are available for all models. Contact your Polaris dealer for more information.Polaris has a wide range of additional accessories available ...

Page 78 - Periodic Maintenance Schedule; Hours of operation are based on a 10 mph average. If service is due at; Improperly performing the procedures marked with a

76 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Hours of operation are based on a 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Item Hours/ Miles Frequency Remarks Brake Syst...

Page 82 - Lubrication Recommendations

80 MAINTENANCE AND LUBRICATION Lubrication Recommendations NOTE: Hours are based on 10 mph average. If service is due at 20 hours, the equivalent odometer reading would be 200 miles. Perform all services at whichever reading is reached first. Lubrication Chart Key " More often under severe use, ...

Page 85 - position

83 MAINTENANCE AND LUBRICATION Lubrication Recommendations (7) (9) (8) (6) 4 O’clock position (6) (11) (10) (12) (14) (15) (13) (13)

Page 86 - Periodic Maintenance Record; Use the following chart to record periodic maintenance.

84 MAINTENANCE AND LUBRICATION 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.

Page 87 - Polaris 2-Cycle Lubricants; Premium Gold Synthetic 2-Cycle Oil

85 MAINTENANCE AND LUBRICATION Lubrication Recommendations Polaris 2-Cycle Lubricants Polaris Premium 2-cycle lubricants are the most advanced formulation of oils, specifically designed for today’s 2-cycle engines. Our ongoing lab and field tests have resulted in a new generation of 2-cycle lubrican...

Page 88 - Premium 4 Synthetic Oil; -Cycle Engines With External Oil Tank

86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Premium 4 Synthetic Oil Polaris Premium 4 All Season Synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It’s a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lub...

Page 89 - Oil and Filter Change; Contact with hot oil may result in serious burns. Do not allow hot

87 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 1. Position the vehicle on a level surface.2. Clean the area around the drain plug, which is located on either the bottom of the oil tank or on the bottom of the engine. 3. Run the...

Page 90 - Loss of oil pump prime could result in engine damage. It’s extremely

88 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change 4-Cycle Engines With External Oil Tank 11. Lubricate the gasket on the new filter with a film of new engine oil. Make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on t...

Page 92 - Polaris Premium 4 synthetic oil.

90 MAINTENANCE AND LUBRICATION Lubrication Recommendations Oil and Filter Change Magnum 330 2x4, Magnum 330 4x4, Trail Boss 12. Remove the dipstick and fill the sump with 2 quarts (1.9 l) of Polaris Premium 4 synthetic oil. 13. Place the gear selector in neutral and set the parking brake.14. Start t...

Page 93 - Transmission Oil Check - Models with Fill Plug; The transmission fill plug is located; Gearcase Oil Fill Chart

91 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 The transmission lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Transmission oil should be c...

Page 94 - Transmission Oil Change - Models with Fill Plug; vehicle to access the fill plug.

92 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - Models with Fill Plug Scrambler 500 4x4, Magnums: 500, 330 4x4, 330 2x4 1. If equipped, remove the propshaft shield from the right side of the vehicle to access the fill plug. 2. Remove the fill plug.3. Remove the t...

Page 95 - Transmission Oil Check - Models with Dipstick

93 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Check - Models with Dipstick On most 2x4 models, the transmission dipstick (1) is located on the right side of the machine. On the Sportsman, the dipstick is located near the rear brake disc.The transmission lubricant level ...

Page 96 - Transmission Oil Change - 2x4 Models

94 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Change - 2x4 Models 7. Tighten the jam nut securely while holding the adjuster bolt.8. Add the proper lubricant through the dipstick hole until the oil level is between the upper and lower limits. Do not overfill. 9. Check f...

Page 97 - Front Gearcase Oil Check; Type A and B; Front Gearcase Oil Change; Gearcase

95 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Check The front gearcase oil level should be checked every six months or 1000 miles (1600 km), whichever comes first. The oil should be changed annually. Use Polaris Premium Synthetic Gearcase Lube (or GL5 80-90 weight gea...

Page 98 - Rear Gearcase Oil Check

96 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Check With the ATV on a level surface, remove the fill plug and view the oil level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2), approximately 1 5/8 ″ below the top of the f...

Page 99 - Counter Balance Oil Check - 400 2-Cycle Engines; Drain Locations

97 MAINTENANCE AND LUBRICATION Lubrication Recommendations Counter Balance Oil Check - 400 2-Cycle Engines The counter balance oil should be checked semi-annually and oil should be added or changed as needed. The oil should be changed annually and before off season storage. If the machine is used in...

Page 100 - Engine Oil Check; The dipstick must be

98 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Check The oil tank is located either on the left side of the vehicle (external tank models)(1) or on the engine (2).1. Position the machine on a level surface.2. Start the engine and let it idle for 20-30 seconds. Stop the engine....

Page 101 - Engine Cooling System; Coolant Level; GEN III

99 MAINTENANCE AND LUBRICATION Engine Cooling System Coolant Level The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle on Gen IV machines, remove the left side panel. See page 111.The fluid level must be maintained between the minimum and maximum marks o...

Page 102 - Radiator Coolant Level; Gen III; Escaping steam can cause severe burns. Never remove the

100 MAINTENANCE AND LUBRICATION Engine Cooling System Radiator Coolant Level NOTE: This procedure is required only if the cooling system has been drained for maintenance and/or repair. However, if the recovery bottle has run dry, the level in the radiator should be inspected and coolant added if nec...

Page 103 - in loss of oil, which will cause serious engine damage. Always

101 MAINTENANCE AND LUBRICATION Engine Cooling System NOTE: To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/4...

Page 104 - Adjustments; Oil Pump - 250 Engines

102 MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 250 Engines 1. Before adjusting the oil pump, check the engine idle RPM and carburetor settings in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn the adjuster (1) in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 cm) o...

Page 105 - Oil Pump - 400 Engines

103 MAINTENANCE AND LUBRICATION Adjustments Oil Pump - 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments in your owner’s manual supplement. 2. Loosen the throttle cable jam nut and turn the adjuster in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 cm) t...

Page 106 - Front Brake

104 MAINTENANCE AND LUBRICATION Adjustments Front Brake The front brakes are hydraulic disc brakes. They’re activated by moving the brake lever toward the handlebar. These brakes are self-adjusting.The following checks are recommended to keep the brake system in good operating condition. Check more ...

Page 107 - Rear Brake

105 MAINTENANCE AND LUBRICATION Adjustments Rear Brake The rear brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Pads should be changed when worn to 3/64 ″ (.1 cm), which is about the thickness of a U...

Page 108 - Toe Alignment; Severe injury or death can result from improper toe alignment and

106 MAINTENANCE AND LUBRICATION Adjustments Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 ″ to 1/4 ″ toe out. 1. Set the handlebars in a straight-ahead position. NOTE: The steering frog can be used as an indicator of whether...

Page 109 - Steering Assembly; dealer for service before operating the vehicle.; Camber and Caster; The camber and caster are non-adjustable.; Rear Spring; Accessory springs are available through your Polaris dealer.

107 MAINTENANCE AND LUBRICATION 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, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non...

Page 110 - Handlebars; Improper adjustment of the handlebars or incorrect torquing of

108 MAINTENANCE AND LUBRICATION Adjustments Handlebars The handlebars can be adjusted for rider preference.1. Locate handlebar bolts (1). On models with a headlight pod, remove the upper headlight pod. On other models, remove the handlebar cover. 2. Loosen the four bolts.3. Adjust the handlebar to t...

Page 111 - Carburetor

109 MAINTENANCE AND LUBRICATION Adjustments Carburetor IMPORTANT: Your Polaris ATV is calibrated at the factory for optimal performance at altitudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F. (4 degrees C.) or higher. Above 6000 feet (1800 m) the engine air/fuel mixt...

Page 113 - Side Panel Removal - Gen IV

111 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal - Gen IV NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times.1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, p...

Page 114 - Wheel Removal; Stop the engine, place the transmission in gear and lock the; Operating your ATV with worn tires, improperly inflated tires,

112 MAINTENANCE AND LUBRICATION Adjustments 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 by placing a suitable stand under the footrest frame. 4. Remove the wheel nuts and remove the ...

Page 115 - Wheel Installation; Bolt Size

113 MAINTENANCE AND LUBRICATION Adjustments Wheel Installation 1. Place the transmission in gear and lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 3. Install the wheel nuts and fing...

Page 116 - Front Wheel Hub Tightening; component operations. All service must be performed by your; Tire Tread Depth; Always replace tires when tread; skidding, which could lead to loss of control and serious injury or

114 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (...

Page 117 - Drive Chain; Regularly lubricate the drive chain with SAE 80-90 lube or an; Washing the drive chain with a high pressure washer or

115 MAINTENANCE AND LUBRICATION Adjustments Drive Chain Polaris ATV drive chains are equipped with o-ring-sealed, permanently greased pins and rollers. However, the outer surfaces of the roller must be lubricated.Always inspect the drive chain prior to operating the vehicle. Check for damaged or mis...

Page 118 - Rear Drive Chain Slack - Concentric Drive Models; this point the chain should have 3/16; Adjusting or operating the ATV with improper rear drive chain

116 MAINTENANCE AND LUBRICATION Adjustments Rear Drive Chain Slack - Concentric Drive Models Check the amount of chain slack in three different locations by moving the vehicle slightly forward to gain slack at the top side of the rear chain. Measure the chain slack at the tightest of the three posit...

Page 120 - Filter Systems; Air Filter Removal and Service - 2-Cycle Engines; Never

118 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Removal and Service - 2-Cycle Engines 1. Remove the ATV seat.2. Release the clips securing the cover assembly to the air box.3. Loosen the clamp securing the filter, and remove the filter.4. Remove the foam pre-filter from the main filter.5. ...

Page 121 - Operation of your vehicle without a breather filter can cause

119 MAINTENANCE AND LUBRICATION Filter Systems Air Filter Service - 4-Cycle 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rins...

Page 122 - Lights; Headlight Lamp Replacement - Scrambler; Poor lighting while driving can result in severe injury or death.

120 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. Headlight Lamp Replacement - Scrambler 1. Remove the wire harness connector from the back of t...

Page 123 - Headlight Lamp Replacement - Trail Blazer

121 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Trail Blazer 1. Remove the front cover and unplug the light harness.2. Remove the rubber cap from the back of the headlight to reveal the retention screw. 3. Remove the small phillips head screw, and carefully remove the bulb from t...

Page 124 - Headlight Lamp Replacement - Gen IV; through the two small openings at the front of the headlight pod.

122 MAINTENANCE AND LUBRICATION Lights Headlight Lamp Replacement - Gen IV 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. 3. Lift the pod slightly while depressing the...

Page 125 - High Beam Adjustment - Gen IV

123 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment - Gen IV The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from...

Page 126 - Headlight Housing Replacement - Gen IV

124 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement - Gen IV 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the ...

Page 127 - Taillight/Brakelight Lamp Replacement

125 MAINTENANCE AND LUBRICATION Lights Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be replaced. 1. Remove the taillight lens cover mounting screws. Remove the lens cover and gasket and set aside for reassembly. 2. Remove the lamp (1) and repla...

Page 128 - Spark Plugs; Spark Plug Removal and Replacement; Using non-recommended spark plugs can result in serious engine; A hot exhaust system and engine can cause serious burns. Wear

126 MAINTENANCE AND LUBRICATION Spark Plugs Refer to your owner’s manual supplement for recommended spark plug and gap specifications. Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has be...

Page 129 - Vehicle Immersion; If your vehicle becomes immersed, major engine damage can

127 MAINTENANCE AND LUBRICATION Vehicle Immersion If it’s impossible to take your ATV to a dealer before starting it, follow the steps outlined below.1. Move the ATV to dry land or at the very least, to water below the foot rests. 2. Check the airbox for any water and dry it if water is present. 3. ...

Page 130 - Spark Arrestor; Failure to heed the following warnings while servicing the spark

128 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow compone...

Page 132 - Recoil Housing; must be behind the heat shield

130 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing after operating the ATV in very wet conditions. This should also be done before storing the ATV.Water will enter the recoil housing if the starter handle is disengaged from the rope guid...

Page 133 - PVT System; When To Use Low Range vs. High Range; Low Range

131 MAINTENANCE AND LUBRICATION PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of “pi...

Page 134 - PVT Drying

132 MAINTENANCE AND LUBRICATION PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating: 1. Remove the drain plug and allow the water to drain. Replace the drain plug. 2. Start the engine a...

Page 135 - Keep the battery terminals and connections free of corrosion. If

133 MAINTENANCE AND LUBRICATION Battery (Conventional) Keep the battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off wit...

Page 136 - Battery; Replenishing Battery Fluid (Conventional Battery); in an explosion and cause serious injury or death. When removing; tablespoon baking soda and one cup water to prevent damage to

134 MAINTENANCE AND LUBRICATION Battery Replenishing Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. The fluid level should be kept between the upper and lower level marks (1).To refill use only distilled water. Tap wate...

Page 137 - Battery Installation; fully charged

135 MAINTENANCE AND LUBRICATION Battery Battery Installation 1. Set the battery in the battery holder.2. With conventional batteries, install the battery vent tube. Sealed batteries do not have a vent tube. NOTE: The vent tube must be free of obstructions and securely installed. If not, battery gase...

Page 138 - charged battery will register 12.8 V or higher.; An overheated battery could explode, causing severe injury or

136 MAINTENANCE AND LUBRICATION Battery Battery Charging (Sealed Battery) For a refresh charge, follow all instructions carefully.1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge t...

Page 139 - Cleaning and Storage; Cleaning the ATV; damage plastic surfaces. Use caution when using these products

137 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 141 for the part numbers of Polaris-recommended products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned ...

Page 140 - Storage Tips; Clean the Exterior; film created by fogging and damage could occur. Never start the

138 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 141 for the part numbers of Polaris-recommended products. Clean the Exterior Make necessary repairs and then clean the ATV thoroughly with mild soap and warm water to remove all dirt and grime. Don’t use harsh detergents or h...

Page 141 - Fog the Engine

139 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 141 for the part numbers of Polaris-recommended products. Fog the Engine 2 Cycle - Use Polaris Fogging Oil and follow the directions on the can. 4-Cycle - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0...

Page 142 - Battery Storage; Do not use tap water; Transporting the ATV

140 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Conventional Battery: Remove the battery and add distilled water to the proper level. Do not use tap water , which may contain minerals that reduce battery life. Apply Polaris di-electric grease to the terminal bolts a...

Page 143 - POLARIS RECOMMENDED PRODUCTS

141 POLARIS RECOMMENDED PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871721 Premium Gold Synthetic 2-Cycle Oil (qt.) 2871281 Premium 4 Synthetic 0W-40 Engine Oil (4-Cycle)(qt.) Gearcase / Transmission Lubricants 2873602...

Page 144 - TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause

142 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low ra...

Page 145 - solutions using the following charts.; Engine Doesn’t Turn Over

143 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...

Page 146 - Engine Backfires

144 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...

Page 147 - Engine Stops or Loses Power

145 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...

Page 148 - WARRANTY; LIMITED WARRANTY

146 WARRANTY LIMITED WARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain ...

Page 150 - HOW TO OBTAIN WARRANTY SERVICE; Engine Oil

148 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states ...

Page 151 - INDEX

149 INDEX A Accessories 75 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments 102-117 . . . . . . . . . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . . . . . . . . Air Filter 118-119 . . . . . . . . . . . . . . . . . . . . . . . . . . . All...

Page 153 - PRINTED IN THE USA

Operate without proper training or instruction. Operate on public roads. A collision can occur with another vehicle. Operate at speeds too fast for your skills or the conditions. Use ALCOHOL or DRUGS before or while operating this vehicle. Carry Passengers. Part No. 9917492 Rev. 05 PRINTED IN THE US...