Page 3 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Features and Controls . . . . . . . . . . . . . . . . . . . 36Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Emission ...
Page 5 - KNOW YOUR VEHICLE; Vehicle Identification Numbers; VIN
5 KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protec-tion of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, i...
Page 6 - SAFETY; Safety Decals and Locations; safety; Discretionary Warning
6 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the de...
Page 7 - General Warning; General
7 SAFETY Safety Decals and Locations General Warning WARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGERNEVER USE ON PUBLIC ROADSNEVER CARRY MORE THAN ONE PASSENGERNEVER USE WITH DRUGS OR ALCOHOLNEVER operate:• with...
Page 8 - Passenger Safety Warning; NEVER; Tire Pressure/Load Warning; MAXIMUM WEIGHT CAPACITY
8 SAFETY Safety Decals and Locations Passenger Safety Warning WARNINGPASSENGER SAFETYTo reduce the risk of SEVERE INJURY or DEATHNEVER CARRY A PASSENGER UNDER AGE 12NEVER CARRY MORE THAN ONE PASSENGERNEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on fo...
Page 9 - Rack Warning; Reverse Override Warning
9 SAFETY Safety Decals and Locations Rack Warning WARNINGDO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7172572 Clutch Cover Warning WARNINGNO STEP•...
Page 10 - Safe Riding Gear; Helmet
10 SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established...
Page 11 - Eye Protection
11 SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When-ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing marki...
Page 12 - Rider Safety; Age Restrictions; WARNING
12 SAFETY Rider Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. WARNING Failure to follow the warnings contained in this manual can result in sev...
Page 13 - Safety Training; RiderCourse; available to you and your eligible family members. This; . You were also provided with
13 SAFETY Rider Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV. P...
Page 14 - CAUTION; NOTE
14 SAFETY Rider Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym-bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual,...
Page 17 - • Always follow proper procedures for crossing the side of a hill. Do
17 SAFETY Rider Safety • Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sha...
Page 18 - • Always check for obstacles or people behind the ATV before operat-; FOR MORE INFORMATION ABOUT ATV SAFETY, call the
18 SAFETY Rider Safety • Always check for obstacles or people behind the ATV before operat- ing in reverse. Be aware that a passenger can obstruct your view. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for you...
Page 19 - Equipment Modifications
19 SAFETY Rider Safety Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modificatio...
Page 36 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override Switch; Engine Stop Switch; Main Key Switch; Use the main key switch to start the engine. See page 59.; OFF
36 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch. NOTE: The override switch also allows activation of 4X4 in reverse, if the 4X4 switch is on. This switch is...
Page 37 - Differential Switch; Operate the vehicle with the switch in; Unlocked Differential:; When the differential is unlocked, the; Worklight Switch
37 FEATURES AND CONTROLS Switches Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel w...
Page 38 - Throttle Lever
38 FEATURES AND CONTROLS Throttle Lever Engine speed and vehicle move-ment are controlled by pressing the throttle lever. The throttle lever 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 design...
Page 39 - Brake Lever
39 FEATURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These 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 riding. When squ...
Page 40 - Master Cylinder/Brake Fluid; Master Cylinder
40 FEATURES AND CONTROLS Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be cl...
Page 41 - Parking Brake; Locking the Parking Brake
41 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake...
Page 42 - Brake Fluid Level; Auxiliary Foot Brake
42 FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel single lever system. T...
Page 43 - Automatic Transmission Gear Selector; Belt Life; Fuel Filter; Do not; Gear
43 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearL: Low GearN: NeutralR: ReverseP: Park Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake. Belt Lif...
Page 44 - the rope abruptly and forcefully to start the engine.; Passenger Seat; Recoil
44 FEATURES AND CONTROLS Recoil Starter (500 EFI) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 59, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope han- dle tightly. Pull slo...
Page 45 - All Wheel Drive System; Switch
45 FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before as...
Page 47 - Engaging Active Descent Control; The ADC system will automatically engage when; Disengaging Active Descent Control; The ADC system will automatically disengage if
47 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. Engaging Active Descent Control The ADC system will automatic...
Page 48 - Instrument Cluster
48 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. The instrument cluster mea-sures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the...
Page 49 - Rider Information Center; - This warning usually indicates
49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All seg-ments will light up for 2.5 seconds at start-up. NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instr...
Page 50 - Standard Modes; Odometer Mode; The odometer records the miles traveled by the ATV.; Trip Meter Mode; Hour Meter Mode; This mode logs the total hours the engine has been in operation.; Tachometer Mode; The engine RPM is displayed digitally.; Clock Mode
50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 36. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odomete...
Page 51 - Diagnostic Mode; hold; the new setting will not be locked into the memory.
51 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any move-ment of the tires will also cause the gauge to exit the diagnostic mode. T...
Page 52 - View this screen to check battery voltage level.; Tachometer Screen; View the tachometer to check engine speed.; X4 Diagnostic Screen
52 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing throug...
Page 53 - Miles/Kilometers toggle
53 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON...
Page 54 - Downloading Codes; Example; Code Definitions
54 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 55 for Blink Codes and Failure Descriptions. Use the follow-ing procedure to download blin...
Page 56 - OPERATION; Fuel Safety
56 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline.• Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or ne...
Page 57 - Engine and Drivetrain Break-in; Check the engine oil level on the dipstick. See page 84. Add oil if
57 OPERATION Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the proce-dures for a proper break-in. Careful treatment of a ne...
Page 58 - Item
58 OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition. Item Remarks Page Passenger seat latch Ensure latch is secure 44 Brake system/leve...
Page 59 - Starting the Engine; Position the vehicle on a level surface.; Sit on the vehicle and move the engine stop switch to RUN.; Turn the ignition key past the ON position to engage the starter.; If the engine does not start, return the key to the OFF position and; Cold Weather Operation
59 OPERATION Starting the Engine 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lock the parking brake. NOTE: The starter interlock will prevent the engine from starting if the trans- mission is in gear and the brake is not engaged. 4. Sit on the vehicle and move t...
Page 60 - Hauling Cargo
60 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo:Never exceed the stated load capacity for this vehicle.Never carry cargo...
Page 61 - Towing Loads; Maximum Towing Capacities; Do not exceed maximum towing capacities. Avoid towing on inclines.
61 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distri-bution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decal...
Page 62 - Driving Procedures; Sit upright with both feet on the footrests and both hands on the
62 OPERATION Driving Procedures 1. Wear protective riding gear. See page 10. 2. Perform the pre-ride inspection. See page 58. 3. Place the transmission in PARK. 4. Lock the parking brake. 5. Mount the vehicle from the left side. 6. Sit upright with both feet on the footrests and both hands on the ha...
Page 63 - Turning the Vehicle; Never turn quickly when; The same leaning technique should be used for turning in reverse.
63 OPERATION Turning the Vehicle Both rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Sl...
Page 64 - Driving with a Passenger
64 OPERATION Driving with a Passenger 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, includ- ing an approved helmet with a rigid chin guard. See page 10. 3. ...
Page 65 - Do not cross a hillside with a passenger on board. See page 68.
65 OPERATION Driving with a Passenger 10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a pas-senger to fall from the vehicle. 11. Do not cross a hillside with a passenger on board. See page 68. 12. A passenger should...
Page 66 - Driving on Slippery Surfaces; Slow down when entering
66 OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Slow down when entering slippery areas. 2. Engage 4X4 before wheels begin to lose trac-tion. 3. Maintain a high level of alertne...
Page 67 - Driving Uphill; Maximum
67 OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 47. 2. Drive straight uphill. 3. Avoid steep hills (15 ° maximum). 4. Keep both feet on the footrests. 5. Shift body weight uphill...
Page 68 - If operating in 2X4 mode, make sure the differential is locked.
68 OPERATION Driving on a Sidehill (Sidehilling) Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions: 1. Slow down. 2. If operating in 2X4 mode, make sure the differential is locked. 3. Do not cr...
Page 69 - Driving Downhill; When driving downhill, follow these precautions:
69 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 47. 2. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 3. Slow ...
Page 71 - slowly
71 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 47. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board...
Page 72 - Driving Through Water; Determine water depths and current before crossing.
72 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both banks have gradual...
Page 74 - Driving Over Obstacles; Be alert! Look ahead and learn to read the terrain you're traveling
74 OPERATION Driving Over Obstacles 1. 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 hang-ing branches. 2. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extr...
Page 75 - Parking on an Incline; Always block the rear wheels on the downhill side.
75 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
Page 76 - Driving in Reverse
76 OPERATION Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.Do not use the override switch unless addition...
Page 77 - Follow these precautions when operating in reverse:
77 OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turni...
Page 78 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; This spark ignition system complies with Canadian ICES-002.
78 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle...
Page 79 - MAINTENANCE; Periodic Maintenance Chart; Severe Use Definition
79 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace par...
Page 80 - Maintenance Chart Key; Perform these operations more often for vehicles subjected to
80 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dea...
Page 83 - Lubrication Guide
83 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and upper control arms are lubricated at the ...
Page 84 - Engine Oil; Oil Recommendations; Polaris recommends the use of Polaris PS-4
84 MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Syn- thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendat...
Page 85 - Position the vehicle on a level; Dipstick
85 MAINTENANCE Engine Oil Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. NOTE: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture col- lecting in the crankcase. If the oil level is over the full/safe m...
Page 88 - Prime the oil pump using the procedure on page 89.
88 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the fi...
Page 89 - Oil Pump Priming; Clamp or pinch off the vent line; Clamp
89 MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between t...
Page 90 - Drain Plug Location
90 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it t...
Page 91 - Place shop towels beneath the oil
91 MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counter-clockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. ...
Page 92 - Transmission Oil; Transmission Oil Level; Drain Plug
92 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 79. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant....
Page 93 - Transmission Oil Change; Place a drain pan under the; Demand Drive Capacities
93 MAINTENANCE Transmission Oil Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. (27-34 Nm). 5. Add 32 oz. (948 ml) of the recommended...
Page 94 - Fluid Level
94 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque...
Page 95 - ADC Fluid Reservoir
95 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door. 2. View the fluid level in the reservoir. If the level is below the minimum mark, remove the cap and add the recommended fluid. 3. Reinstall the cap securely. Secure the access do...
Page 96 - Cooling System; Recovery Bottle Coolant; Maintain the coolant level; Recovery
96 MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding ...
Page 97 - Radiator Coolant; Open the front box cover and; Radiator Cap
97 MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been dra...
Page 98 - Brakes; Hand Brake; Always keep brake fluid at an adequate
98 MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and...
Page 99 - Toe Alignment; Position the vehicle on a; Measure the distance; String
99 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a straight-ahead position. 3. Tie a length of string betw...
Page 100 - Steering Assembly; Grasp the rear of the side panel near the rear cab. With a firm; Footwell Removal; Remove the six screws on; Screws
100 MAINTENANCE 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. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel ...
Page 101 - Tires; Tire Tread Depth
101 MAINTENANCE Tires Refer to the specifications section beginning on page 138 for recom-mended tire type, size and pressure. Tire Tread Depth Always replace tires when tread depth is worn to 1/8" (3 mm) or less. Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention...
Page 102 - Wheel Installation; Place the wheel on the hub with the valve stem toward the outside; Wheel Nut Torque Specifications; Nut Type; Lug Nut; Cast Aluminum
102 MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower th...
Page 103 - Air Filter; and remove the air box cover.; Reinstall the filter into the air box; Main Filter
103 MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry. 5. Reinstall the pre-filt...
Page 104 - Remove the left side; Breather Filter
104 MAINTENANCE Breather Filter/Hose (500 EFI) The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 100. 2. Remove the hose clamps from the fil-ter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently thro...
Page 105 - Fuse Replacement; Fuse; Speedometer
105 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replace-ment. NOTE: Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door. 2. Remove th...
Page 106 - Lights; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight
106 MAINTENANCE 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 1. Remove the two screws on the lower front corners of the headlight pod. 2. Remove...
Page 107 - High Beam Adjustment; Low Beam Adjustment; Phillips Screw
107 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 1. Position the vehicle on a level surface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2....
Page 108 - Headlight Housing Replacement
108 MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the...
Page 109 - Lower Headlamp Replacement; Harness
109 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the...
Page 110 - Spark Plugs; Spark Plug Recommendations; Rotate the spark plug cap 1/4 turn and pull it off the spark plug.; Plug Condition; New Spark Plug
110 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 138 for the recom-mended spark plug type and gap for your vehicle. Torque spark plugs to specification. Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the...
Page 111 - Spark Plug Inspection; Normal Spark Plug; Remove the drain screw on the
111 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indi-cates the proper type and heat range for the engine and the service. NOTE: The tip shoul...
Page 112 - Vehicle Immersion
112 MAINTENANCE Vehicle Immersion 1. If it's impossible to take your ATV to a dealer before starting it, fol- low the steps outlined below. 2. Move the ATV to dry land or at the very least, to water below the footrests. 3. Check the air box. If water is present, dry the air box and replace the filte...
Page 113 - Spark Arrestor; Place the transmission in; Exhaust
113 MAINTENANCE Spark Arrestor Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler. 1. Remove the arrestor clean-out plug from the bottom of the muffler. 2. Place the transmission in PARK. 3. Start the engine. 4. Quickly squeeze and release the throttle...
Page 114 - PVT System
114 MAINTENANCE PVT System WARNING Failure to comply with the instructions in this warning can result in severe injury or death.Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any...
Page 116 - When To Use Low Range and High Range; Condition
116 MAINTENANCE PVT System When To Use Low Range and High Range 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 operat-ing. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow th...
Page 117 - Battery; Conventional Battery; External
117 MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little mainte-nance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Batter...
Page 118 - Battery Removal; battery sideways, which could spill electrolyte.
118 MAINTENANCE Battery Battery Removal 1. Loosen the battery hold-down bolt. 2. Remove the battery cover. 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out ...
Page 119 - Battery Installation; Ensure that the battery is fully charged.; Coat the terminals with dielectric grease or petroleum jelly.
119 MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the bat-tery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 121 before installing the battery. 1. Ensure that the batter...
Page 120 - Battery Storage; Lower
120 MAINTENANCE Battery Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed...
Page 121 - fully charged
121 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leak- ing or spilled electrolyte during charging. See page 118. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...
Page 122 - State of
122 MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: Always verify battery condition before and 1-2 hours after the end of charging. State of Charge Voltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None, check at ...
Page 123 - Cleaning and Storage; Washing the Vehicle; and the lower parts last.; Washing Tips
123 MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various components. The best and safest way to clean your Polaris vehicle is with a garden hose and a pail of mild soap and water. 1. Us...
Page 124 - Polishing the Vehicle; Polishing Tips; • Avoid the use of automotive products, some of which can scratch the
124 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the follow-ing items: • Wheel bearings• Ra...
Page 125 - Wash chrome wheels frequently. Use a mild detergent. Never use; Removing Corrosion
125 MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, pre-serve wheel life and ensure a "like new" appearance for many years. NOTE: Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more s...
Page 126 - Storage Tips; Clean the Exterior; disperse through the entire fuel delivery system.; Oil and Filter
126 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 123. Stabilize the Fuel 1. Fill the fuel tank. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow the instructions on the containe...
Page 127 - Fluid Levels; Remove the spark plug and add 2-3 tablespoons of engine oil. To
127 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 79.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase (if equipped)• Tran...
Page 128 - Inspect and Lubricate; See pages 120-121 for storage and charging procedures.; Accessories
128 MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 79. Battery Storage See pages 120-121 for storage and charging procedures. Storage Area/Covers Set the ...
Page 129 - Transporting the ATV
129 MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Secure the fuel cap and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps ...
Page 130 - ADJUSTMENTS; Camber and Caster; Adjuster
130 ADJUSTMENTS Camber and Caster The camber and caster are non-adjust-able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. NOTE: Accessory springs are available through your Polaris dealer....
Page 131 - Handlebars; The handlebars can be adjusted for rider preference.; Torque the front two bolts to; Handlebar
131 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height. NOTE: Be sure the handlebars do not contact the gas tank or any other part of the machine when turned ...
Page 132 - Throttle Body/Idle RPM; Adjust throttle cable freeplay at the handlebar.; Lock Nut
132 ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar....
Page 133 - TROUBLESHOOTING; Possible Cause
133 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading. Starting out going up a steep incline Use low range or turn around using the K-turn (see page 70). Driving at low RPM or ground speed (3-7 MPH) Drive at ...
Page 134 - Engine Doesn't Turn Over
134 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possib...
Page 135 - Engine Pings or Knocks
135 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularly, Stalls or Misfires Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Possible Cau...
Page 136 - Engine Stops or Loses Power
136 TROUBLESHOOTING Engine Stops or Loses Power Engine Overheating Possible Cause Solution Out of fuel Refuel, cycle key to ON position three times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective s...
Page 137 - POLARIS PRODUCTS; Part; Engine Lubricant; Additives / Miscellaneous
137 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcas...
Page 138 - SPECIFICATIONS; Sportsman 500 Touring
138 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 Touring Maximum Weight Capacity 600 lbs. (272 kg) (includes operator, passen-ger, cargo, accessories) Dry Weight 770 lbs. (349 kg) (base model) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Recei...
Page 140 - Sportsman 800 Touring
140 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 800 Touring Maximum Weight Capacity 600 lbs. (272 kg) (includes operator, passen-ger, cargo, accessories) Dry Weight 795 lbs. (361 kg) (base model) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack Capacity 180 lbs. (82 kg) Recei...
Page 142 - WARRANTY; LIMITED WARRANTY
142 WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-ITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for ...
Page 143 - WARRANTY COVERAGE AND EXCLUSIONS:
143 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 ...
Page 144 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
144 WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-TICULAR 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 145 - Exported Vehicles; How to Get Service
145 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-TION.This policy does not apply to vehicles that have received authorization for expo...
Page 146 - Notice
146 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of th...
Page 148 - MAINTENANCE LOG
148 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
