Page 3 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6Features and Controls . . . . . . . . . . . . . . . . . . . 34Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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, 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
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 4X4 in reverse, if the 4X4 switch is on. This switch is...
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 - Fuel Tank Cap; Fuel
41 FEATURES AND CONTROLS Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gaso-line with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel . Fuel Filter The in-line fuel filter should be replaced by your dealer after every 200 ...
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 59, 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 - All Wheel Drive System; When the switch is on 2X4, the ATV is in two-wheel drive at all times.; Switch
44 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 46 - Engaging Active Descent Control; The ADC system will automatically engage when; Disengaging Active Descent Control; The ADC system will automatically disengage if
46 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 47 - Instrument Cluster
47 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 48 - Rider Information Center; - This warning usually indicates
48 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 49 - 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
49 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 50 - Diagnostic Mode; hold; Do not turn the key switch off until the display stops flashing or
50 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 51 - View this screen to check battery voltage level.; Tachometer Screen; View the tachometer to check engine speed.; X4 Diagnostic Screen
51 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 52 - Miles/Kilometers toggle
52 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 53 - Downloading Codes; Example
53 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 80. 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 Brake system/lever travel Ensure proper operation 37 93 Brake fl...
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; Towing Loads
60 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 62 - Driving Safely; Driving Procedures; Sit upright with both feet on the footrests and both hands on the
62 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 63 - Turning the Vehicle
63 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 64 - Driving on Slippery Surfaces; Engage 4X4 before
64 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 4X4 before wheels begin to lose traction. 3. Maintain a high...
Page 65 - Driving Uphill; Whenever traveling uphill, follow these precautions:; Maximum
65 OPERATION Driving Safely 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 46. 2. Drive straight uphill. 3. Avoid steep hills (25 ° maximum). 4. Keep both feet on the footrests. 5. Shift you...
Page 66 - Steer slightly into the hill to maintain vehicle direction.
66 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 67 - Driving Downhill; When driving downhill, follow these precautions:
67 OPERATION Driving Safely 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 46. 2. Shift your weight uphill. 3. Drive straight downhill. 4. Slow down. 5. Squeeze the brake lever gradually. NOTE...
Page 68 - slowly
68 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. Always move the 4X4 switch to ADC 4X4 before ascending or des...
Page 69 - Driving Through Water; Determine water depths and
69 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 70 - Driving Over Obstacles
70 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 71 - Driving in Reverse; Always avoid backing
71 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 72 - Parking on an Incline; Always block the rear wheels on the downhill side.
72 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.
Page 73 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; This spark ignition system complies with Canadian ICES-002.
73 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 74 - MAINTENANCE; Periodic Maintenance Chart; Severe Use Definition
74 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 75 - Maintenance Chart Key; Perform these operations more often for vehicles subjected to
75 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 79 - Lubrication Guide; Front Prop Shaft Yoke
79 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. 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 80 - Engine Oil; Oil Recommendations; Polaris recommends the use of Polaris PS-4; Oil Level; Position the vehicle on a level; Dipstick
80 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 81 - Oil and Filter Change
81 MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. 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...
Page 82 - Place shop towels beneath the oil
82 MAINTENANCE Engine Oil Oil and Filter Change 10. Reinstall the screen fitting and rotate the fitting clockwise a mini- mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-ting until the nipple of the fitting aligns with the mark on the tank. NOTE: Do not over-tighten. Maximum tor...
Page 83 - Prime the oil pump using the procedure on page 84.; Then stop
83 MAINTENANCE Engine Oil Oil and Filter Change 17. Reinstall the drain plug.Torque to 14 ft. lbs. (19 Nm). 18. Remove the dipstick. 19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick. NOTE: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially. 20. Place the transm...
Page 84 - Oil Pump Priming; Clamp or pinch off the vent line; Clamp
84 MAINTENANCE Engine Oil 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 ...
Page 85 - Transmission Oil; Oil Check; Drain Plug
85 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. 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 86 - Oil Change; Place a drain pan under the; Drain
86 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 87 - Demand Drive Capacities; Demand Drive with ADC
87 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals out-lined in the Periodic Maintenance Chart beginning on page 74. We rec-ommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of compone...
Page 88 - Fluid Check
88 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 89 - View the fluid level in the reservoir.; ADC Fluid Reservoir
89 MAINTENANCE Active Descent Control (ADC) Fluid Two fluid levels must be maintained on your vehicle, the demand drive fluid and the ADC fluid. See page 87 for demand drive fluid mainte-nance. Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning...
Page 90 - Fluid Change; change, allow the vehicle to sit for at least 30 minutes.; Fill the reservoir to the maximum line with fresh ADC fluid.
90 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 91 - Cooling System; Recovery Bottle Coolant; Maintain the coolant level
91 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 92 - Radiator Coolant; Radiator Cap
92 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 93 - Brakes; Hand Brake; Always keep brake fluid at an adequate
93 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 94 - Toe Alignment; Position the vehicle on a; Measure the distance; String
94 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 95 - Side Panel Removal; Grasp the rear of the side panel near the rear cab. With a firm; Footwell Removal; Remove the four screws on; Screws
95 MAINTENANCE Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. Pull the panel downward and rearward to remove it. 3. When reinstalling side panels, align the fastene...
Page 96 - Steering Assembly
96 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. Tires Refer to the specifications section beginning on page 134 for recom-me...
Page 97 - Tires; Tire Tread Depth
97 MAINTENANCE Tires 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 are critical com-ponent operations. All service must be performed by your authorized Polaris dealer. Whee...
Page 98 - 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
98 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 99 - Air Filter; Release the air box cover; Reinstall the filter into the air box and tighten the clamp. Do not; Main Filter
99 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 101 - Fuse Replacement; Remove the suspect fuse; Fuse Panel
101 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. NOTE: Spare fuses are provided in a compartment on th...
Page 102 - Lights; Headlight Lamp Replacement; Remove the two screws on the lower front corners of the headlight
102 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 103 - High Beam Adjustment; Low Beam Adjustment; Phillips Screw
103 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 104 - Headlight Housing Replacement
104 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 105 - Lower Headlamp Replacement; Harness
105 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 106 - 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
106 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 134 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 107 - Spark Plug Inspection; Normal Spark Plug; Recoil Housing; Remove the drain screw on the
107 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 108 - Vehicle Immersion
108 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 109 - Spark Arrestor; Place the transmission in; Exhaust
109 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 110 - PVT System
110 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 112 - When To Use Low Range and High Range; Condition
112 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 113 - Battery; Conventional Battery; External
113 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 114 - Battery Removal; battery sideways, which could spill electrolyte.
114 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 115 - Battery Installation; Ensure that the battery is fully charged.; Verify that cables are properly routed.
115 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 117 before installing the battery. 1. Ensure that the batter...
Page 116 - Battery Storage; Lower
116 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 117 - fully charged
117 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 114. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as nee...
Page 118 - State of
118 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 119 - Cleaning and Storage; Washing the Vehicle; and the lower parts last.; Washing Tips
119 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 120 - Polishing the Vehicle; Polishing Tips; • Avoid the use of automotive products, some of which can scratch the
120 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 121 - Wash chrome wheels frequently. Use a mild detergent. Never use; Removing Corrosion
121 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 122 - Storage Tips; Clean the Exterior; disperse through the entire fuel delivery system.; Oil and Filter
122 MAINTENANCE Cleaning and Storage Storage Tips Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 119. 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 123 - Fluid Levels; Remove the spark plug and add 2-3 tablespoons of engine oil. To
123 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 74.• Demand drive unit (front gearcase)• ADC fluid (ADC models) (change every two years)• Rear gearcase (if equipped)• Tran...
Page 124 - Inspect and Lubricate; See pages 116-117 for storage and charging procedures.; Accessories
124 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 74. Battery Storage See pages 116-117 for storage and charging procedures. Storage Area/Covers Set the ...
Page 125 - Transporting the ATV
125 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 126 - ADJUSTMENTS; Camber and Caster; The camber and caster are non-adjustable.; Rear Spring; Adjuster
126 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 127 - Handlebars; The handlebars can be adjusted for rider preference.; Torque the front two bolts to; Handlebar
127 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 128 - Throttle Body/Idle RPM; Adjust throttle cable freeplay at the handlebar.; Lock Nut
128 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 129 - TROUBLESHOOTING; Possible Cause
129 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 68). Driving at low RPM or ground speed (3-7 MPH) Drive at ...
Page 130 - Engine Doesn't Turn Over
130 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 131 - Engine Pings or Knocks
131 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 132 - Engine Stops or Loses Power
132 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 133 - POLARIS PRODUCTS; Part; Engine Lubricant; Additives / Miscellaneous
133 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 134 - SPECIFICATIONS
134 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 500 EFI Maximum Weight Capacity 485 lbs. (220 kg) Fuel Capacity 4.13 gal. (15.6 l) Engine Oil Capacity 2 qts. (1.9 l) Coolant Capacity 2.7 qts. (2.5 l) Demand Drive Fluid Capacity 9.3 oz. (275 ml) Transmission Oil Capacity 32 oz. (948 ml...
Page 135 - Clutching
135 SPECIFICATIONS Clutching NOTE: *EBS models require no helix/spring adjustment Sportsman 500 EFI Shift Type Side Lever (H/L/N/R/P) Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 16.30:1 Gear Reduction, Forward 10.49:1 Drive Ratio, Front 3.82:1 Tires/Pressure, Front 26x8-12 / 5 psi (34.5 KPa)...
Page 136 - WARRANTY; LIMITED WARRANTY
136 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 137 - WARRANTY COVERAGE AND EXCLUSIONS:
137 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 138 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
138 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 139 - Exported Vehicles; How to Get Service
139 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 140 - Notice
140 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 142 - MAINTENANCE LOG
142 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
