Page 3 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Features and Controls . . . . . . . . . . . . . . . . . . . 34Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Emission ...
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, and the protection of our environment. Read and understand your owner's manual, which includes valuable informa-tion about all aspects of your vehicle, including safe operating pro...
Page 6 - SAFETY; Safety Decals and Locations; safety; General 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 - Discretionary Warning; Tire Pressure/Load Warning; Warning
7 SAFETY Safety Decals and Locations Discretionary Warning WARNING• Never operate this ATV on HILLS steeper than 25 degrees 25 ° . To pre- vent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually. • REVERSE operation can be dangerous even at low speeds. Steering beco...
Page 8 - “No Passenger” Warning
8 SAFETY Safety Decals and Locations “No Passenger” Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER oper...
Page 9 - Clutch Cover Warning; Rack Warning, Front and Rear; Hitch Capacity Label
9 SAFETY Safety Decals and Locations Clutch Cover Warning WARNINGNO STEP• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM...
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 - Operator Safety; Age Restrictions; WARNING
12 SAFETY Operator Safety Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. WARNING Failure to follow the warnings contained in this manual can result in severe injury or death.A Polaris ATV is not a toy and can be hazardous to operate....
Page 13 - Safety Training; RiderCourse; available to you and your eligible family members. This; . You were also provided with
13 SAFETY Operator Safety Safety Training ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your ATV...
Page 14 - CAUTION; NOTE; note
14 SAFETY Operator 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 manu...
Page 18 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the; Equipment Modifications
18 SAFETY Operator Safety FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342- 3764. Equipment Modifications We are concerned for the safety of our customers and for the gen...
Page 34 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override Switch
34 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 All Wheel Drive in reverse, if the AWD switch is on. Th...
Page 35 - Engine Stop Switch; Main Key Switch; OFF
35 FEATURES AND CONTROLS Switches Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: Both the main switch and the engine stop switch will shut off all electri- cal power to the ve...
Page 36 - Throttle Lever
36 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 37 - Brake Lever
37 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 38 - Master Cylinder/Brake Fluid; Master Cylinder
38 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 39 - Parking Brake; Locking the Parking Brake
39 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 40 - Brake Fluid Level; Auxiliary Foot Brake
40 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 41 - Choke; Fuel Tank Cap; Fuel Valve; Fuel
41 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 55 for correct choke and throttle settings during start-ing. Fuel Valve The fuel valve is located on the bottom of the fuel tank. Access the fuel valve through the right front w...
Page 42 - Automatic Transmission Gear Selector; Belt Life; Gear
42 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 43 - Grasp the recoil starter rope; the rope abruptly and forcefully to start the engine.; Recoil Starter
43 FEATURES AND CONTROLS Recoil Starter If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 55, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. 2. Pull slowly so yo...
Page 44 - There is no limit to the length of time the vehicle may remain in AWD.; Engaging AWD; AWD
44 FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4, the ATV is in two-wheel drive at all times. When the switch is on AWD, the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will...
Page 45 - Engaging Active Descent Control; The ADC system will automatically engage when; Disengaging Active Descent Control; The ADC system will automatically disengage if
45 FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. If your ATV is equipped with Active Descent Control, always engage AWD before ascending or descending a hill. Engaging Activ...
Page 46 - Instrument Cluster
46 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures dis-tance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's ...
Page 47 - Rider Information Center; - This warning usually indicates
47 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 48 - 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
48 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 34. NOTE: The transmission cannot be in reverse when using this feature. Odometer Mode The odomete...
Page 49 - Diagnostic Mode; Do not turn the key switch off until the display stops flashing or
49 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 50 - View this screen to check battery voltage level.; Tachometer Screen; View the tachometer to check engine speed.; AWD Diagnostic Screen
50 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. AWD Diagnostic Screen The gauge indicates whether or not current is flowing throug...
Page 51 - hold; Miles/Kilometers toggle
51 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 52 - OPERATION; Fuel Safety
52 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 53 - Engine and Drivetrain Break-in; sary to maintain the level between the safe and add marks.
53 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 54 - Item
54 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 Brake system/lever travel Ensure proper operation 37 90 Brake fl...
Page 55 - Starting the Engine; Position the vehicle on a level surface.; Tension
55 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. Turn the fuel valve on. 5. Si...
Page 56 - Turn the ignition key past the ON position to engage the starter.
56 OPERATION Starting the Engine 8. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts. 9. If the engine does not start, return the key to the OFF position and wait five seconds before attempt...
Page 57 - Cold Weather Operation
57 OPERATION Cold Weather Operation If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must b...
Page 58 - Hauling Cargo; Towing Loads
58 OPERATION Hauling Cargo Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi-cations section of the owner's manual and on the safety decal...
Page 60 - Driving Safely; Driving Procedures; Sit upright with both feet on the footrests and both hands on the
60 OPERATION Driving Safely Driving Procedures 1. Wear protective riding gear. See page 10. 2. Sit upright with both feet on the footrests and both hands on the handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your...
Page 61 - Turning the Vehicle
61 OPERATION Driving Safely Turning the Vehicle Your ATV is 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 tracti...
Page 62 - Driving on Slippery Surfaces; Engage AWD before
62 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez-ing weather, follow these precautions: 1. Slow down when enter- ing slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high...
Page 63 - Driving Uphill; Maximum
63 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 45. 2. Drive straight uphill. 3. Avoid steep hills (25 ° maximum). 4. Keep both feet on the foot...
Page 64 - Steer slightly into the hill to maintain vehicle direction.
64 OPERATION Driving Safely 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. Shift your weight uphill. 3. Keep your feet on the footrests....
Page 65 - Driving Downhill; When driving downhill, follow these precautions:
65 OPERATION Driving Safely Driving Downhill When driving downhill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 45. 2. Shift your weight uphill. 3. Drive straight downhill. 4. Slow down. 5. Squeeze the brake l...
Page 66 - slowly
66 OPERATION Driving Safely Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill. 2. If your ATV is equipped with Active Descent Control, engage A...
Page 67 - Driving Through Water; Determine water depths and
67 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recom-mended depth equal to the bot-tom of the footrests. Follow these procedures when operat-ing through water: 1. Determine water depths and current before crossing. 2. Choose a crossing where both ...
Page 68 - Driving Over Obstacles
68 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle. ...
Page 69 - Driving in Reverse; Always avoid backing
69 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open t...
Page 70 - Parking on an Incline; Always block the rear wheels on the downhill side.
70 OPERATION Driving Safely 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. 5. Turn the fuel valve off...
Page 71 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; This spark ignition system complies with Canadian ICES-002.
71 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 72 - MAINTENANCE; Periodic Maintenance Chart; Severe Use Definition
72 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 73 - Maintenance Chart Key; Perform these operations more often for vehicles subjected to
73 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 77 - Lubrication Guide
77 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: The a-arms and lower control arms are lubricated at the ...
Page 78 - Engine Oil; Oil Recommendations
78 MAINTENANCE Engine Oil Oil Recommendations 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 lubrication performance and protection. ...
Page 79 - Oil Level; Position the vehicle on a level; Dipstick
79 MAINTENANCE Engine Oil Oil Level 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 mark, chang...
Page 80 - Oil and Filter Change
80 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to thr...
Page 81 - Place shop towels beneath the oil; Prime the oil pump using the procedure on page 82.; Then stop
81 MAINTENANCE Oil and Filter Change 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Using a clean dry cloth, clean the filter sealing surface on the crank-case. 14. Lubricate the o-ring on the new filter with a film of fre...
Page 82 - Oil Pump Priming; Clamp or pinch off the vent line; Clamp
82 MAINTENANCE Oil and Filter Change 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 the end of the oil tan...
Page 83 - Transmission Oil; Oil Check; Drain Plug
83 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 72. 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 84 - Oil Change; Place a drain pan under the; Demand Drive Capacity
84 MAINTENANCE Transmission Oil 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 com-pletely. 4. Clean and reinstall the drain plug. Torque to 22 ft. lbs. (30 Nm). 5. Add 32 oz. (948 ml) of the recommended oil. 6. Reinstall...
Page 85 - Fluid Check
85 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level. 2. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 3. Reinstall the fill plug. Torque to...
Page 86 - Open the front box cover and pull; ADC Fluid Reservoir
86 MAINTENANCE Active Descent Control (ADC) Fluid If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 84 for demand drive fluid maintenance. Check and change the ADC fluid level at the intervals outl...
Page 87 - Fluid Change; change, allow the vehicle to sit for at least 30 minutes.; Fill the reservoir to the maximum line with fresh ADC fluid.
87 MAINTENANCE Active Descent Control (ADC) Fluid Fluid Change 1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes. 2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves (one on each side of the d...
Page 88 - Cooling System; Recovery Bottle Coolant; Maintain the coolant level
88 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 89 - Radiator Coolant; Open the front box cover; Radiator Cap
89 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 90 - Brakes; Hand Brake; Always keep brake fluid at an adequate
90 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 91 - Toe Alignment; Position the vehicle on a; Measure the distance; String
91 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 92 - Steering Assembly; Grasp the rear of the side panel near the rear cab. With a firm; Footwell Removal; Remove the four screws on; Screws
92 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 n...
Page 93 - Tires; Tire Tread Depth
93 MAINTENANCE Tires Refer to the specifications section beginning on page 128 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 94 - 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
94 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 the...
Page 95 - Air Filter; Release the air box cover; Reinstall the filter into the air box and tighten the clamp. Do not; Main Filter
95 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 96 - Lights; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight
96 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 97 - High Beam Adjustment; Low Beam Adjustment; Phillips Screw
97 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 98 - Headlight Housing Replacement
98 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 99 - Lower Headlamp Replacement; Harness
99 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 100 - 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
100 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 128 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 101 - Spark Plug Inspection; Normal Spark Plug; Recoil Housing; Remove the drain screw on the
101 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 102 - Vehicle Immersion; Drain Screw
102 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 103 - Spark Arrestor; Place the transmission in; Exhaust
103 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 104 - PVT System
104 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 106 - When To Use Low Range and High Range; Condition
106 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 107 - Battery; Conventional Battery; External
107 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 108 - Battery Removal; battery sideways, which could spill electrolyte.
108 MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 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...
Page 109 - Battery Installation; Ensure that the battery is fully charged.; Verify that cables are properly routed.
109 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 111 before installing the battery. 1. Ensure that the batter...
Page 110 - Battery Storage; Lower
110 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 111 - fully charged
111 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 108. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...
Page 112 - State of
112 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 113 - Cleaning and Storage; Washing the Vehicle; and the lower parts last.; Washing Tips
113 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 114 - Polishing the Vehicle; Polishing Tips; • Avoid the use of automotive products, some of which can scratch the
114 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 115 - Wash chrome wheels frequently. Use a mild detergent. Never use; Removing Corrosion
115 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 116 - Storage Tips; Clean the Exterior; disperse through the fuel in the tank and carburetor.; Oil and Filter
116 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 113. 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 117 - Fluid Levels; Remove the spark plug. Rotate the piston to BDC and pour two
117 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 72.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase (if equipped)• Tran...
Page 118 - Inspect and Lubricate; See pages 110-111 for storage and charging procedures.; Accessories
118 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 72. Battery Storage See pages 110-111 for storage and charging procedures. Storage Area/Covers Set the ...
Page 119 - Transporting the ATV
119 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, oil cap and seat. 5. Always tie the frame of the ATV to the transporting unit securely with suitable s...
Page 120 - ADJUSTMENTS; Camber and Caster; The camber and caster are non-adjustable.; Rear Spring; Remove the upper headlight; Adjuster
120 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. 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 121 - Carburetor; Carburetor/Engine Idle RPM Adjustment; Start the engine and allow it to; Idle Screw
121 ADJUSTMENTS Carburetor 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 mixture becomes overly rich and the engine ...
Page 122 - Throttle Cable Freeplay; Adjust throttle cable freeplay at the handlebar.; Lock Nut
122 ADJUSTMENTS Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate ...
Page 123 - TROUBLESHOOTING; Possible Cause
123 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 66). Driving at low RPM or ground speed (3-7 MPH) Drive at ...
Page 124 - Engine Doesn't Turn Over
124 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connection...
Page 125 - Engine Pings or Knocks
125 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 126 - Engine Stops or Loses Power
126 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 Overuse of choke Inspect, clean and/or replace spark plugs Water is ...
Page 127 - POLARIS PRODUCTS; Part; Engine Lubricant; Additives / Miscellaneous
127 POLARIS PRODUCTS Part Number Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic G...
Page 128 - SPECIFICATIONS
128 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 Gross Vehicle Weight 1200 lbs. (544 kg) Maximum Weight Capacity 485 lbs. (220 kg) (operator, cargo, accesso-ries) Dry Weight 696 lbs. (316 kg) Fuel Capacity 4.25 gal. (16 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil Capacit...
Page 129 - Jetting Chart; ALTITUDE
129 SPECIFICATIONS Jetting Chart Clutching Chart Sportsman 500 Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 9.5" (24 cm) travel Shift Type Side Lever (H/L/N/R/P) Gear Reducti...
Page 130 - WARRANTY; LIMITED WARRANTY
130 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 131 - WARRANTY COVERAGE AND EXCLUSIONS:
131 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 132 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
132 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 133 - Exported Vehicles; How to Get Service
133 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 134 - Notice
134 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 136 - MAINTENANCE LOG
136 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
