Polaris 2001 ATV Universal ATV- User Manual

CONTENTS UNDERSTANDING WARNINGS 1-2 . . . . . . . . . . . . . . . . . . . . . . . . . . SAFETY WARNING AND OPERATION DECALS 3-11 . . . . . . . . . . . DAILY PRE-RIDE INSPECTION 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION WARNINGS 13-33 . . . . . . . . . . . . . . . . . . . . ....

1 UNDERSTANDING WARNINGS ATTENTION: This is an ADULT VEHICLE ONLY; not a toy. Operation is prohib- ited for anyone under 16 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 variou...

2 UNDERSTANDING WARNINGS SAFETY ALERT WARNINGS identify special instructions or procedures which, if not correctly followed, could result in personal inju- ry, or loss of life. Read all WARNINGS in this manual carefully. Follow their instructions to remain safe. The following precautionary signal wo...

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

4 SAFETY WARNING AND OPERATION DECALS 1 7079083 E 1997 IF OWNER’S MANUAL IS MISSING, CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT. WARNING

6 SAFETY WARNING AND OPERATION DECALS F Never operate this ATV on HILLS steeper than 25 degrees To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually. 25 ° F REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipove...

8 SAFETY WARNING AND OPERATION DECALS 4 5 (Refer to your Owner’s Manual Supplement for your vehicle’s 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...

9 SAFETY WARNING AND OPERATION DECALS 7 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 l...

12 DAILY PRE-RIDE INSPECTION Use the following checklist to verify your machine is in proper work- ing order each time you ride. Item/Inspection Procedure 1. Tires - check condition and pressures2. Fuel and oil tanks - fill both tanks to their proper levels3. All brakes - check operation, adjustment...

13 OPERATION WARNINGS 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 differ- ent situations and on different types of terrain.HOW TO AVOID THE HAZARDBeginning a...

14 OPERATION WARNINGS POTENTIAL HAZARDCarrying a passenger on this ATV.WHAT CAN HAPPENGreatly reduces your ability to balance and control this ATV.Could cause an accident, resulting in harm to you and/or your passenger.HOW TO AVOID THE HAZARDNever carry a passenger. The long seat is to allow the op-...

15 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV on paved surfaces, including side- walks, paths, parking lots, and driveways.WHAT CAN HAPPENThe ATV tires are designed for off-road use. Paved surfaces may seriously affect handling and control of the ATV, and may cause the vehicle to go out o...

17 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV without wearing an approved helmet, eye protection and protective clothing.WHAT CAN HAPPENOperating without an approved helmet increases your chances of a severe head injury or death in the event of an accident.Operating without eye protection...

18 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV after consuming alcohol or drugs.WHAT CAN HAPPENCould seriously affect your judgment.Could cause you to react more slowly.Could affect your balance and perception.Could result in an accident.HOW TO AVOID THE HAZARDNever consume alcohol or drug...

22 OPERATION WARNINGS POTENTIAL HAZARDFailure to use extra care when operating on excessively rough, slippery or loose terrain.WHAT CAN HAPPENCould cause loss of traction or vehicle control, which could result in an accident, including an overturn.HOW TO AVOID THE HAZARDDo not operate on excessively...

24 OPERATION WARNINGS POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as de- scribed in the Owner’s Manual. See pages 79 through 82.Always check the terrain careful...

25 OPERATION WARNINGS POTENTIAL HAZARDGoing down a hill improperly.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for going down hills as described in the Owner’s Manual. See page 81. NOTE: A special technique is required wh...

26 OPERATION WARNINGS POTENTIAL HAZARDImproperly crossing hills or turning on hills.WHAT CAN HAPPENCould cause loss of control or cause ATV to overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you have mastered the turning technique as described in the Owner’s Ma...

27 OPERATION WARNINGS POTENTIAL HAZARDStalling, rolling back- wards or improperly dismounting while climbing a hill.WHAT CAN HAPPENCould result in ATV overturning.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If you lose all forward speed:Keep weight uphill.Apply the brakes.Lock ...

28 OPERATION WARNINGS POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENCould cause loss of control or a collision. Could cause the ATV to overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Use extreme caution when riding over large obstacles, such a...

29 OPERATION WARNINGS POTENTIAL HAZARDOperating this ATV through deep or fast flowing water.WHAT CAN HAPPENTires may float, causing loss of traction and loss of control, which could lead to an accident.HOW TO AVOID THE HAZARDAvoid operating the ATV through deep or fast flowing wa- ter. If you cannot...

31 OPERATION WARNINGS POTENTIAL HAZARDOverloading this ATV or carrying or towing cargo im- properly.WHAT CAN HAPPENCould cause changes in vehicle handling which could lead to an accident.HOW TO AVOID THE HAZARDNever exceed the stated load capacity for this ATV.Cargo should be properly distributed an...

34 VEHICLE IDENTIFICATION NUMBERS 2 1 Record these numbers from your ATV in the spaces provided. 1. Frame VIN (found on the lower left side of the frame tube) 2. Engine Serial Number (Right front side of engine crankcase) Remove the spare key and store in a safe place. Your key can be duplicated onl...

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

36 CONTROL AND PARTS FUNCTIONS Important Safeguards D Always back slowly avoiding excessive speed and do not use the reverse speed override switch system unless addi- tional power is required for vehicle movement. D Avoid turning at sharp angles in reverse. D Avoid backing on steep inclines. Light S...

37 CONTROL AND PARTS FUNCTIONS Indicator Lights Each Polaris ATV has indicator lights. The configuration of these lights differs with individual models and not every model is equipped with all the lights. The information in your Owner’s Manual Supplement and in the following box will help you identi...

38 CONTROL AND PARTS FUNCTIONS Electronic Speedometer Some Polaris ATVs are equipped with an electronic speedometer which senses vehicle speed from the right hand front wheel. The electronic speedometer measures distance in miles and kilome- ters as well as hours of operation. The speedometer also i...

39 CONTROL AND PARTS FUNCTIONS When the programmed hours are reached, SEr hr will light; when the programmed distance is reached, SErdIS will light. Each time the vehicle is started, the reminder will turn on and remain lit until the button is pushed or the speedometer is reprogrammed for the next s...

40 CONTROL AND PARTS FUNCTIONS Setting Service Hours (cont.) 6. Repeat step 4 and 5 to program the digits for the service interval selected. (i.e. for service interval of 50 hours set the display to show: 00050 H ) 7. To save the changes press and hold the button when any one of the digits is flashi...

41 CONTROL AND PARTS FUNCTIONS TO SET SERVICE DISTANCE Same as setting Service Hours, but toggle to SET dIS . TO CHECK WHEN SERVICE IS DUE BY DISTANCE Same as setting Service Hours, but toggle to SET dIS . TO CLEAR THE SERVICE REMINDER FROM THE DIS- PLAY The reminder will remain in the LCD window un...

42 CONTROL AND PARTS FUNCTIONS Engine Throttle and Choke Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever (1) is spring loaded and engine speed returns to idle when the lever is released.This vehicle is equipped with a Polaris Electro...

43 CONTROL AND PARTS FUNCTIONS Front and Rear Brakes The brake fluid in the master cyl- inder, which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through the plastic reservoir (1), and should be maintained between the indi- cated max (2) and min (...

45 CONTROL AND PARTS FUNCTIONS Parking Brake Setting the Parking Brake - A 1. Squeeze the left hand brake lever two or three times and hold it. 2. Rotate the park brake lock (1) into the notches on the mas- ter cylinder body. Release the brake lever. 3. To release the parking brake lock, squeeze the...

46 CONTROL AND PARTS FUNCTIONS Setting the Parking Brake - B 1. Squeeze the left hand brake lever two or three times and hold it. 2. Push the park brake lock (2) into the notches on the mas- ter cylinder body. Release the brake lever. 3. To release the parking brake lock, squeeze the brake le- ver. ...

47 CONTROL AND PARTS FUNCTIONS Auxiliary Brake Your Polaris ATV has an auxiliary brake provided as a safety fea- ture. It is located on the inside of the right floor board and is oper- ated by the right foot. It is intended as a backup to the main brake system, especially if the main system becomes ...

48 CONTROL AND PARTS FUNCTIONS Automatic Transmission Gear Selector Operation Shift patterns depend on the type of vehicle you own. Please check your Owner’s Manual Supplement to define your ma- chine’s shift pattern. The transmission gear selector is located on the right side of the vehicle directl...

49 CONTROL AND PARTS FUNCTIONS Manual Shift Operation The engine can only be started with the transmission in neu- tral.Turn the key to “on” and ensure the stop switch is in the run position.The neutral indicator light should be on. If it is not, shift the foot pedal down ( or up and down, if in Re-...

50 CONTROL AND PARTS FUNCTIONS Gear Shift Pedal The gear shift pedal is above the left floorboard. One full stroke of the pedal shifts the transmission to the next higher or lower gear in the shifting sequence. The pedal automatically returns to the horizontal position when released.The Xpedition ha...

51 CONTROL AND PARTS FUNCTIONS Shifting to Reverse With the ATV running and in neutral, hold the brake lever and push the Reverse/Override button on the LH control. Depress the gear shift pedal one stroke. The reverse indicator light will come on. Slowly release the brake lever and press throttle co...

52 CONTROL AND PARTS FUNCTIONS Exclusive Demand 4 Drive System (All Wheel Drive) Polaris 4 wheel drive ATVs are equipped with a unique, Polaris exclusive, Demand 4 Drive (AWD) system which is activated by a switch (1) on the right handlebar. When the switch is “off” the ATV is in 2 wheel drive at al...

53 CONTROL AND PARTS FUNCTIONS Engage the Demand 4 Drive switch before getting into condi- tions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before turning the Demand 4 Drive switch on. Disengaging Wheel Hubs When backing up while in Demand 4 Drive an...

55 CONTROL AND PARTS FUNCTIONS Engine Cooling System Radiator Coolant Level Inspection NOTE: This procedure is only required 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 in- spected and coolant ...

58 CONTROL AND PARTS FUNCTIONS Engine Fuel and Oil System Fuel System The fuel tank filler cap (1) is located directly behind the handlebar. Refer to your owner’s Manual Sup- plement for tank capacity. Use either leaded or un- leaded gasoline with a minimum pump octane number of 87 R+ M/2 oc- tane. ...

59 CONTROL AND PARTS FUNCTIONS Oil System On models with a two cycle engine, the engine oil injection tank filler cap (2) is located on the front of the machine. Refer to your Owner’s Manual Supplement to determine the type of engine your vehicle has. The tank ca- pacity is 2 quarts (1.9 l). On mode...

60 CONTROL AND PARTS FUNCTIONS Polaris 2-Cycle Lubricants Polaris has a family of premium oils available for use in all our prod- ucts and highly recommends their use. The only oils recom- mended for Polaris 2-cycle ATVs are Polaris Premium 2-cycle oil or Premium Gold Synthetic 2-cycle oil.Polaris P...

61 CONTROL AND PARTS FUNCTIONS 4-Cycle Premium 4 Synthetic Lubricant Polaris Premium 4 All Season Synthetic engine oil has been spe- cially formulated for use in Polaris 4-cycle engines. It is a fully syn- thetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication ...

63 CONTROL AND PARTS FUNCTIONS Recoil Starter Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter located on the right side of the machine will allow vehicle operation until repairs can be made. Polaris 4-cycle engines are equipped with automatic decompres- s...

64 CONTROL AND PARTS FUNCTIONS Drain the recoil housing after operating the ATV in very wet condi- tions. This should also be done before storing the ATV. The drain screw is located at the bottom of the recoil housing. Using a wrench, remove the screw. Reinstall screw once housing has been drained. ...

65 STARTING THE ENGINE Procedure for Starting a Cold Engine NOTE: (A) - top view of the choke lever; (B) - choke button 2 1 3 A B 1. Place the transmission in neutral and reset the parking brake.2. Turn the fuel tank valve to ON.3. Sit on the vehicle.4. Move the choke to the FULL (1) position.5. Tur...

66 STARTING THE ENGINE 8. On models with a key ignition, turn the key to start the vehicle.9. Do not press the throttle while starting the engine. 10. Activate the starter for a maximum of five seconds, releasing the key or button when the vehicle starts. If engine does not start, release the starte...

67 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 perfor...

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

71 CARRYING LOADS Your ATV has been designed to carry a certain amount of load. CARGO WEIGHT should be evenly distributed (1/3 on the front and 2/3 on the rear) and mounted as low as possible. When oper- ating over rough or hilly terrain, reduce speed and cargo to main- tain stable driving condition...

72 CARRYING LOADS 2/3 of Load on Rear Rack 1/3 of Load on Front Rack Important Safeguards To reduce risk of injury or machine damage when carrying loads, read and follow the warnings listed below: D REDUCE SPEED AND ALLOW GREATER DISTANCE FOR BRAKING WHEN CARRYING CARGO. D CARGO WEIGHT DISTRIBUTION ...

75 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 thrott...

76 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...

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

78 RIDING Never engage Demand Drive while wheels are spinning as severe damage to drive train may occur. Failure to exercise care when operating the ATV on slippery surfaces can be dangerous.Loss of tire traction and vehicle control can result in an acci- dent, including an overturn.

79 RIDING Traveling Uphill 25 _ Maximum Whenever traveling uphill always travel straight uphill and: 1. Avoid steep hills (25 _ maximum). 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...

80 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...

81 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...

82 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...

83 RIDING Crossing Streams Your Polaris ATV can operate through water up to maximum recommended depths reaching the footrests. Before fording streams always: 1. Determine water depths and current.2. Choose a crossing where both banks have gradual inclines.3. Proceed slowly, avoiding rocks and obstac...

85 RIDING Trail Obstacles Keep Alert! Look ahead and learn to read the trail as you ride. Stay on the right side of the trail, if possible, and be constantly alert for hazards such as logs, rocks and low hanging branches. Not all obstacles are visible. Travel with caution on trails. severe injury or...

86 RIDING Backing Up 1. Avoid backing up on steep inclines.2. Always 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 throttle is open. Loss of c...

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

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

90 PVT SYSTEM OPERATION On Polaris ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH, due to the system’s dependence on engine speed. For example, when operating at a gro...

91 PVT SYSTEM OPERATION When To Use Low Range vs. High Range The following lists provide a guideline for when to use low range rather than high. Low Range: S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain (swamps, mountains, etc.) at low ground speeds High R...

92 BATTERY Battery Replenishing the Battery Fluid A poorly maintained battery will deteriorate rapidly. Check the bat- tery fluid level often. The fluid level should be kept between the upper and lower level marks.To refill use only distilled water. Tap water contains minerals which are harmful to a...

93 BATTERY Battery Removal 1. Disconnect hold down straps holding the electrical box and bat- tery in position and remove battery cover. 2. Remove the battery vent tube from the battery. 3. Disconnect the black (negative) battery cable first. 4. Disconnect the red (positive) battery cable next. 5. L...

95 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...

96 MAINTENANCE Spark Arrestor Spark Arrestor The exhaust pipe must be periodically purged of accumulated car- bon as follows: 1. Remove the clean out plugs (1) located on the bottom of the muffler as shown above. 2. Place the transmission in neutral and start the engine. Purge accumulated carbon fro...

98 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...

99 MAINTENANCE Periodic Maintenance Schedule Careful periodic maintenance will help keep your vehicle in the saf- est, most reliable condition. Inspection, adjustment and lubrica- tion intervals of important components are explained in the follow- ing chart on the following pages. Maintenance interv...

101 MAINTENANCE Periodic Maintenance Schedule (Cont.) " More often under severe use, such as dirty or wet conditions to purge water or dirt contamination from grease fittings and other critical components. L Emission Control System Service (California - 4-Cycle) NOTE: Some 4-Cycle models may hav...

105 MAINTENANCE Lubrication Recommendations Item Lube Rec Method Frequency* 1. Engine Oil (2-Cycle) Polaris Injection Oil Fill oil tank. See page 58. As needed, when refuel- ing 2.Engine OIl (4-Cycle) Polaris Premium 4 Synthet- ic 0W40 Add to proper level on dip- stick. See page 61. Check level dail...

106 MAINTENANCE Lubrication Recommendations Operating Range Full 4. Transmission (dipstick) 6. Front Prop Shaft (U-Joint) Fill plug 5. Front Gear Case 4. Transmission (plug) 7. Propshaft Yoke Fill plug

110 MAINTENANCE Lubrication Recommendations 16. Swing Arm Bushings 15. Rear Axle Bearing 17. Upper Control Arm 19. Rear Wheel Hub Bearing Carrier 20. Rear Anti- Roll Bar 18. Lower Control Arm INDEPENDENT REAR SUSPENSION 18. Lower Control Arm

111 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.

112 MAINTENANCE Handlebar Adjustment Your ATV has handlebars which can be adjusted for your personal fit. 1. Locate handlebar bolts. On models with a head- light pod, it will be neces- sary to remove the upper headlight pod. On other models remove the han- dlebar cover. 2. Loosen the four bolts. 3. ...

113 MAINTENANCE The following items should be checked occasionally for tightness; or if they have been loosened for maintenance service. Wheel Nut Torque Specifications Bolt Size Specification Front 3/8 ″ 20 Ft. Lbs. Rear 3/8 ″ 20 Ft. Lbs. Rear 1/2 ″ 50 Ft. Lbs. NOTE: All nuts that have a cotter pin...

114 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. NOTE: Accessory springs are available through your Polaris dealer. Rear Spring Adjustment Cam Rear Spring Adjustment

116 MAINTENANCE Air Cleaner - 2 Cycle EnginesFilter Removal and Service Procedure 1. Remove the ATV seat. 2. Unsnap the four clips holding the cover assembly to the air box. 3. Loosen clamp securing the filter and remove the filter.4. Remove the foam pre-filter from the main filter.5. Wash pre-filte...

117 MAINTENANCE Cleaning the Main Filter NOTE: It is advisable to replace the filter when it is dirty. However, in an emergency it is permissible to clean the main filter if you ob- serve the following practices. 1. Never immerse the filter in water since dirt can be transferred to the clean air sid...

118 MAINTENANCE Breather Filter and Hose - 4-Cycle Engines With Dry Sump* 1. Remove the clamps and pull the filter out of the hoses. NOTE: It will not be necessary to remove the lower hose from the engine. 2. Inspect filter for debris. Blow through gently in direction of arrow on filter to check for...

119 MAINTENANCE Steering Inspection The steering assembly of the machine should be checked periodi- cally 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 Y...

121 MAINTENANCE Front Brake The front brakes are hydraulic disc brakes which are activated by the brake lever being moved toward the handlebar. These brakes are self-adjusting and require no adjustment.The following checks are recommended to keep the brake system in good operating condition. How oft...

122 MAINTENANCE Rear and Auxiliary BrakeRear 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 system is self adjusting and requires no maintenance other than periodic checks of the pads for wear. D Pads sh...

123 MAINTENANCE Oil Pump Adjustment Procedure 400 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor adjustments which are found in the owner’s manual supplement. 2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 cm) of ...

124 MAINTENANCE Oil Pump Adjustment Procedure - 250 Engines 1. Before adjusting the oil pump, check engine idle RPM and carburetor ad- justments which are found in the owner’s manual sup- plement. 2. Loosen throttle cable jam nut and turn adjuster in or out until there is 1/16 ″ - 1/8 ″ (.16 - .32 c...

125 MAINTENANCE Oil Pump Bleeding Procedure 1. Fill the oil reservoir with Polaris injector oil. 2. Loosening the bleeder screw is only necessary when the oil supply line has been disconnected from the pump or the oil res- ervoir and supply line have been completely run out of oil. In these cases, l...

126 MAINTENANCE Engine Choke Adjustment 2-Cycle Engines When the choke is in the full off position, the choke plunger must be seated on the fuel passageway in the carburetor. If the plunger is not seated on the passageway, the engine will flood or run too rich, causing spark plug fouling and very po...

127 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 min- utes. 2. Place the transmission ...

128 MAINTENANCE Choke Adjustment Procedure 4-cycle Engine s Toggle Switch 1. Push choke knob to the full off position. 2. Slide boot off in-line cable adjuster sleeve. Loosen adjustment locknut on in- line cable adjuster. 3. Turn cable sleeve adjusting nut clockwise on in-line ad- juster until 1/8 ″...

131 MAINTENANCE Spark Plugs Check your owner’s manual supplement for recommended spark plug and gap.The spark plug and its condition is indicative of engine operation. The spark plug firing end condition should be read after the engine is warmed up and the vehicle is driven at higher speeds. Immedi-...

132 MAINTENANCE Cylinder Head/Cylinder Base Fastener Torque (2-Cycle Models) Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours. Oil and Filter Change The recommended oil change interval is 100 hours, 1000 miles, or every...

133 MAINTENANCE Oil Filter and Change (4-Stroke models with an external oil tank) 1. Place vehicle on a level surface. 2. Clean area around drain plug which is found at the bottom of the oil tank or on the bottom of the engine. 3. Run engine for two to three minutes until warm. Shut engine off. 4. P...

141 MAINTENANCE Transmission Lubrication - Models with Fill Plug Scrambler 500 4x4, Xplorer 400, Xplorer 4x4, Magnum 500, Magnum 325 4x4, Magnum 325 2x4 The transmission fill plug is located on the right side of the machine behind the propshaft shield or footwell.The transmission lubricant level sho...

142 MAINTENANCE Transmission Oil Changing Procedure 1. Remove the four screws on the footwell and gently pull outward for access. Remove propshaft shield from the right side of the vehicle (Scrambler 500 4x4, Xplorer 4x4). 2. Remove fill plug. 3. Remove transmission drain plug located on the bottom ...

143 MAINTENANCE Transmission Lubrication - Models with Dipstick Transmission Dipstick For most 2x4 models, a transmission dipstick is located on the right side of the machine. On the Sportsman, the dipstick is lo- cated near the rear brake disc.The transmission lubricant level should be checked mont...

145 MAINTENANCE Sportsman Transmission Oil Changing Procedure 1. Remove fill plug/dipstick.2. Remove transmission drain plug side and drain the oil. Catch and discard used oil properly. 3. Clean and reinstall the drain plug. 4. Add 32 oz. (948 ml) Polaris Premium Synthetic Gearcase Lubricant (PN 287...

146 MAINTENANCE Front Gearcase Lubrication The front gearcase fill plug is lo- cated as shown.The front gearcase lubricant level should be checked every six months or 1000 miles (1600 km), whichever comes first. Front gearcase oil should be changed annually. Type A - With the ATV on a level surface,...

147 MAINTENANCE Rear Gearcase Lubrication With the ATV on a level surface, remove fill plug and visually in- spect the lubricant level through the fill hole (1). Lubricant should be kept even with the center of the drillpoint (2) approximately 1 5/8 ″ below the top of the fill hole. NOTE: Do not add...

148 MAINTENANCE Counter Balance Lubrication - 400 Engines 1. Counter Balance Drain 2. Crankcase Drain 3. Recoil Drain 4. Starter Pinion Drain The counter balance oil should be checked semi- annually and oil should be added or changed as nec- essary. The oil should be changed annually, espe- cially b...

149 MAINTENANCE Procedure for Adding Oil 1. Remove seat and locate dipstick (1). 2. Remove dipstick. Oil level is shown on dipstick. 3. Add SAE 10W30 oil with a transmission fluid funnel until oil is at the proper level on the dipstick. If over- filled, excess oil will be ex- pelled through the vent...

151 MAINTENANCE Wheel Installation 1. With the transmission in gear and the parking brake locked, place the wheel in the correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. 2. Attach the wheel nuts and finger ...

152 MAINTENANCE Drive Chain Inspection and Adjustment Polaris ATV drive chains are equipped with O-ring sealed perma- nently greased pins and rollers. However, it is still necessary to lu- bricate the outer surfaces of the roller. Always inspect the drive chain prior to operating the vehicle, checki...

153 MAINTENANCE Rear Drive Chain Slack Adjustment (Models with Concentric Drive) Check the amount of chain slack by moving the vehicle slightly for- ward to gain slack at the top side of the rear chain. At this point the chain should have 3/16 ″ -3/8 ″ (.48 cm - .95 cm) deflection (1). If the chain ...

154 MAINTENANCE Adjustment Procedure 1. Loosen chain guide. 2. Loosen two eccentric lock- ing bolts (2). 3. Loosen caliper mounting bracket bolts located under the axle. 4. Insert a pin punch through the sprocket hub and into the eccentric axle housing. 5. Roll the ATV forward or back to adjust chai...

155 MAINTENANCE Headlight Lamp Replacement Headlight Lamp Replacement - Scrambler 1. Remove wire harness connector from the back of headlight.2. Grasp bulb housing, turn counterclockwise and remove bulb.3. Install bulb into headlight housing and rotate clockwise firmly. NOTE: Bulb is to be positione...

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

157 MAINTENANCE Headlight Lamp Replacement (Trail Blazer) 1. Remove front cover and unplug the light harness. 2. Remove rubber cap from back of headlight to reveal retention screw. 3. Remove small phillips head screw, and carefully remove bulb from housing. 4. Insert new bulb into housing and tighte...

160 MAINTENANCE Headlight Lamp Replacement (Gen IV ) 1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 2. Lift the pod lightly while depressing the tabs. 3. Remove the screw in the back of the headlight pod 4. Lift pod ...

162 MAINTENANCE Headlight Housing Replacement 1. Using a small flat blade screwdriver, push in on the lock tab through the two small openings at the front of the headlight pod. 2. Lift the pod lightly while depressing the tabs. 3. Remove the screw in the back of the headlight pod 4. Remove three Phi...

163 MAINTENANCE Taillight/Brakelight Lamp Replacement If the taillight/brakelight does not work the lamp may need to be re- placed. 1. From the rear of the taillight re- move two screws holding lens cover in place and remove lens cover. 2. Remove lamp (A) and replace it with recommended lamp. 3. Tes...

164 MAINTENANCE Cleaning Your ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few pre- cautions, your ATV can be cleaned much like an automobile. Washing If a high pressure type car wash system is used, extreme care must b...

165 MAINTENANCE Storage Tips Cleaning - Outside...Make necessary repairs and then clean the ATV thoroughly with a mild soap and warm water solution to re- move all dirt and grime. Don’t use harsh detergents or high pres- sure washers. Some detergents deteriorate rubber parts - use dish soap type cle...

166 MAINTENANCE * Fog The Engine - 2 Strokes - Polaris Fogging Oil (PN 2870791) follow directions on the can. 4-Strokes - Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole use a section of clear 1/4 ″ hose and a small plastic squeeze bottle...

167 MAINTENANCE * If you choose not to use Polaris fogging Oil, perform the following procedure. 1. Support the front end of the machine so the engine is level or tilted slightly rearward. 2. Remove spark plug(s). Rotate piston to BDC and pour approxi- mately two ounces of Polaris 2 Cycle Injector o...

168 MAINTENANCE Carburetor Adjustments If the vehicle is to be operated at various altitudes and tempera- tures, certain adjustments can be made to improve its operation and driveability. Above 6000 feet (1800 m) the engine air/fuel mix- ture becomes overly rich. An engine loses approximately 3% of ...

169 TROUBLESHOOTING Clutch Drive Belt & Cover Related Issues: Diagnosis Possible Causes Solutions/What to do Loading the ATV into a pickup or tall trailer when in high range. Shift transmission to low range dur- ing loading of the ATV to prevent belt burning. Starting out going up a steep inclin...

171 TROUBLESHOOTING Procedures The following information is provided to help you identify probable causes for questions you may have about the operation of your ATV. See your Polaris dealer with any additional questions you may have. ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark P...

173 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 ...

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

175 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 ...

INDEX 176 Air Cleaner 116-117 . . . . . . . . . . . Air Filter, Scramblert 500 117 . . All Wheel Drive 52 . . . . . . . . . . . Backing Up 86 . . . . . . . . . . . . . . . Battery Installation 93 . . . . . . . . . Battery Maintenance 92 . . . . . . . Battery Removal 93 . . . . . . . . . . Brake, Aux...