Page 3 - WARNING; The engine exhaust from this product contains
A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342- 3764 for assistance. WARNING The engine exhaust from this product contains chemicals known to the State of C...
Page 4 - WELCOME; RANGER
1 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles• All-terrain vehicles (ATVs)• RANGER utility vehicles • Victory motorcycles We believe Polaris sets a ...
Page 6 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Features and Controls . . . . . . . . . . . . . . . . . . . 26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Emis...
Page 7 - INTRODUCTION
4 INTRODUCTION 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 indicates a potential personal injury hazard...
Page 9 - Vehicle Identification Numbers
6 INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key number) and mating it with one o...
Page 10 - SAFETY; Safety Training; available to you and your eligible family members. This; . You were also provided with
7 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. Polaris strongl...
Page 11 - Safe Riding Gear; Helmet
8 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 12 - Eye Protection; Equipment Modifications
9 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 markin...
Page 13 - Safety Warnings; Operating Without Instruction
10 SAFETY Safety Warnings Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for pr...
Page 14 - Handling Gasoline; Exposure to Exhaust
11 SAFETY Safety Warnings Handling Gasoline 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 spa...
Page 15 - Protective Apparel
12 SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident.Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles...
Page 16 - Operating on Pavement
13 SAFETY Safety Warnings Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.Avoid operating the ATV on pavement. ATV tires are des...
Page 17 - Physical Control of the ATV
14 SAFETY Safety Warnings Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of balance and ejection from the ATV. If the operator's foot is not firmly planted on the footrest, it co...
Page 18 - Descending Hills Improperly; Crossing Hillsides
15 SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.• Always follow proper procedures for travel- ing down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling down-hill. Se...
Page 19 - Stalling While Climbing a Hill
16 SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.• Always maintain a steady speed when climbing a hill. If all forward speed is lost:• Keep body weight uphill.• Apply the brakes.• Lock the par...
Page 20 - Operating on Slippery Terrain
17 SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.Do not operate on excessively rough, slippery or loose terrain. Always use extra cau...
Page 21 - Operating Improperly in Reverse
18 SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 55. Before shifting into reverse gear, always check for obstacles or people...
Page 22 - Operating Over Obstacles
19 SAFETY Safety Warnings Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn.Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always foll...
Page 23 - Improper Cargo Loading
20 SAFETY Safety Warnings Improper Cargo Loading Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.• Never exceed the stated load capacity for this ATV.• Cargo should be properly distributed and securely attached.•...
Page 24 - Operating a Damaged ATV
21 SAFETY Safety Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills S...
Page 25 - Safety Labels and Locations; safety; General Warning
22 SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels ...
Page 26 - Discretionary Warning
23 SAFETY Safety Labels and Locations Discretionary Warning WARNING• Never operate this ATV on HILLS steeper than 25 degrees 25 ° . To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill. • REVERSE operation can be dangerous even at low speeds. Steering beco...
Page 27 - “No Passenger” Warning
24 SAFETY Safety Labels and Locations “No Passenger” Warning WARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH. 7175378 Tire Pressure/Load Warning WARNINGImproper tire pressure or overloading can cause loss of control. Loss of control can re...
Page 28 - Age 16 Warning; Reverse Override Warning
25 SAFETY Safety Labels and Locations Age 16 Warning WARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or death.NEVER operate this ATV if you are under age 16. 7175374 Rack Warning, Front and Rear WARNING• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage o...
Page 29 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override Switch; Engine Stop Switch
26 FEATURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button. WARNING! Pressing the override button while the throttle is open can cause ...
Page 30 - Headlight Switch; See page 36 for all wheel drive information.; Throttle Lever
27 FEATURES AND CONTROLS Switches Headlight Switch Use the headlight switch to turn the lights on and off. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. All Wheel Drive Switch See page 36 for all wheel drive information. Throttle...
Page 31 - Brake Lever
28 FEATURES AND CONTROLS Brake Lever Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward ...
Page 32 - Parking Brake; Locking the Parking Brake
29 FEATURES AND CONTROLS Parking Brake Locking the Parking Brake 1. Place the transmission in gear. 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 33 - reduce
30 FEATURES AND CONTROLS Auxiliary Foot Brake Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake ...
Page 34 - Brake Fluid
31 FEATURES AND CONTROLS Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidl...
Page 35 - Hand Brake; Position the vehicle on a; Foot Brake
32 FEATURES AND CONTROLS Brake Fluid Hand Brake The master cylinder is located on the left handlebar. Main-tain the fluid level 1/4" (6.3 mm) below the top edge of the master cylinder. Do not over-fill. 1. Position the vehicle on a level surface. Make sure the handlebars are straight. 2. View th...
Page 36 - Choke; Refuel when the instrument gauge indicates a low fuel level.; Fuel Filter
33 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 44 for correct choke and throttle settings during start-ing. Fuel Tank Cap Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level su...
Page 37 - Automatic Transmission Gear Selector
34 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. H: High GearN: NeutralR: Reverse To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears w...
Page 38 - Grasp the recoil starter rope
35 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 44, 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 39 - There is no limit to the length of time the vehicle may remain in AWD.; Engaging AWD
36 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 40 - Instrument Cluster; Miles/Kilometers Toggle; as often as needed to reach the odometer mode.
37 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 distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's s...
Page 41 - Rider Information Center; This; Modes; The odometer records the distance traveled by the ATV.
38 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 3 seconds at start-up. 1. Gear Indicator - This indicator displays gear shifter position.N = Neutral (Green)R = Reverse (Amber) 2. E...
Page 42 - OPERATION; Oil Cooler Recommendations; Always install the accessory oil cooler when; Operating Conditions
39 OPERATION Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your ...
Page 43 - Engine and Drivetrain Break-in
40 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 67. Add oil if neces- sary to maintain the level between the safe and add marks. ...
Page 44 - Safe Operation Practices
41 OPERATION Safe Operation Practices 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to oper-ate this vehicle. 3. Never carry a pa...
Page 45 - Know Your Riding Area/Tread Lightly
42 OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the opera-tion of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by con-tacting your Polaris dealer, a local r...
Page 46 - Item
43 OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Item Remarks Page Brake system/lever travel Ensure prope...
Page 47 - Starting the Engine; choke knob out until it stops.
44 OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-venti- lated area. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not e...
Page 48 - Turn the ignition key past the ON position to engage the starter.; Cold Weather Operation
45 OPERATION Starting the Engine 9. 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. NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to ...
Page 49 - Driving Procedures; Sit upright with both feet on the footrests and both hands on the
46 OPERATION Driving Procedures 1. Wear a helmet and eye protection. See page 8. 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 path of tr...
Page 50 - Turning the Vehicle
47 OPERATION 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 traction slightly. To...
Page 51 - Driving on Slippery Surfaces; Do not operate on excessively rough, slippery or loose terrain.
48 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. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage AWD before ...
Page 52 - Driving Uphill; Always check the terrain carefully before ascending any hill.
49 OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly ter-rain. Improper procedure could cause loss of control or overturn. When-ever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. Avoid steep hills (25 ° maximum). 3. Always check the...
Page 53 - If crossing a sidehill is
50 OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A...
Page 54 - Driving Downhill; When driving downhill, follow these precautions:
51 OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Avoid steep hills (25 ° maximum). 2. Shift body weight uphill. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Squeeze the brake lever gradually. Applying...
Page 55 - slowly
52 OPERATION 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. Leave the transmission in forward and shut off the engine. 3. Dismount on th...
Page 56 - Driving Through Water; Choose a crossing
53 OPERATION Driving Through Water Your ATV can operate through water with a maxi-mum recommended depth equal to the bottom of the footrests. Follow these pro-cedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have...
Page 57 - Driving Over Obstacles; Follow these precautions when operating over obstacles:
54 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for haz- ards such as logs, rocks and low hanging branches. 3. Travel slowly and ...
Page 58 - Driving in Reverse; Follow these precautions when operating in reverse:
55 OPERATION 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 the throttle sud...
Page 59 - Hauling Cargo
56 OPERATION Hauling Cargo Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:REDUCE SPEED AND ALLOW GREATER DIST...
Page 60 - Towing Loads; not exceed the rear rack capacity.
57 OPERATION Hauling Cargo Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over roug...
Page 61 - Parking on an Incline; Always block the rear wheels on the downhill side.
58 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 gear. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. 5. Turn the fuel valve off.
Page 62 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; This spark ignition system complies with Canadian ICES-002.
59 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 63 - MAINTENANCE; Periodic Maintenance Chart; Severe Use Definition
60 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 64 - Maintenance Chart Key; Have an authorized Polaris dealer perform these services.
61 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X Perform these ...
Page 68 - Lubrication Guide
65 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri-odic Maintenance Chart beginning on page 60. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS Performance Synthetic 2...
Page 69 - Engine Oil; Oil Recommendations; Polaris recommends the use of Polaris PS-4; Oil Specifications
66 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 70 - Oil Level; Position the vehicle on a level
67 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the ATV. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Start the engine. Allow it to idle for 30 seconds. Stop the engine. 5. Remov...
Page 71 - Oil and Filter Change; Reinstall the drain plug with a new sealing
68 MAINTENANCE Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the pa...
Page 72 - Clean the filter sealing area on the
69 MAINTENANCE Oil and Filter Change 11. Place towels under the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 12. Clean the filter sealing area on the engine. 13. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition. 14. Install the...
Page 73 - Transmission Oil; Transmission Oil Recommendations
70 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 60. Maintain the oil level at the bottom of the fill plug hole. See page 109 for the part numbers of Polaris products. The fill plug is located o...
Page 74 - Oil Check
71 MAINTENANCE Transmission Oil Oil Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Check the oil level. 6. Add oil as needed. Do not overfill. 7. Reinstall the fill plug. Torque to specif...
Page 75 - Oil Change
72 MAINTENANCE Transmission Oil Oil Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use a 15 mm wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use a 15 mm wrench. 7. Allow the oil to...
Page 76 - Demand Drive Fluid Recommendations
73 MAINTENANCE Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the inter-vals outlined in the Periodic Maintenance Chart beginning on page 60. We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of c...
Page 77 - Fluid Check
74 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Check 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Check the oil level. 6. Add the recommended oil as needed to bring the level ...
Page 78 - Fluid Change
75 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Change 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the fill plug. Use an 8 mm Allen wrench. 5. Place a drain pan under the gearcase. 6. Remove the drain plug. Use an 11 mm...
Page 79 - Brakes; Brake Inspections
76 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommended to keep the brake syst...
Page 80 - Toe Alignment
77 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. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignmen...
Page 81 - Steering Assembly; Grasp the top of the side panel and pull it outward to remove it.; Footwell Removal; Remove the two screws on the bottom of the footwell.
78 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 top of the side panel an...
Page 82 - Tires; Tire Tread Depth
79 MAINTENANCE Tires Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual...
Page 83 - Wheel Removal; Place a suitable stand under the
80 MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 5. Place a suitable stand under...
Page 84 - Wheel Installation; Place the wheel on the wheel; Wheel Nut Torque Specifications; Nut Type
81 MAINTENANCE Tires Wheel Installation 1. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation. 2. Install the wheel nuts finger tight. 3. Lower the vehicle to the ground. 4. Torque the wheel nuts to specificati...
Page 85 - Air Filter/Breather Filter
82 MAINTENANCE Air Filter/Breather Filter 1. Position the vehicle on a level surface. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Remove the seat. 5. Release the air box cover clips, and remove the air box cover. 6. Remove the air filter. 7. Remove the sleeve from the filter. 8....
Page 86 - Lights; Headlight Beam Adjustment; Observe the headlight aim on the wall. The most intense part of the
83 MAINTENANCE Lights Headlight 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. 2. Place the transmission in n...
Page 87 - Headlamp Replacement; Lamp Replacement
84 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility. Headlamp Replaceme...
Page 88 - Recoil Housing; Remove the drain screw on the
85 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi-tions. Drain the housing before storing the vehicle. Make sure the hous-ing is completely dry before reinstalling the drain plug. 1. Place the transmission in gear. 2. Lock the parking brake. 3. St...
Page 89 - Spark Plugs; Spark Plug Recommendations; Rotate the spark plug cap; Plug Condition
86 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 114 for the recom-mended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always us...
Page 90 - Spark Plug Inspection; Inspect the electrodes for wear; Spark Plug Condition; Normal Spark Plug
87 MAINTENANCE Spark Plugs Spark Plug Inspection 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. Verify that the gap is at specification before installation. 5. Reverse the procedure for spark plug installation. Torque to specification. Spark Plug Condition Norma...
Page 91 - Vehicle Immersion
88 MAINTENANCE Vehicle Immersion If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined belo...
Page 92 - Spark Arrestor
89 MAINTENANCE Spark Arrestor Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind ...
Page 93 - PVT System
90 MAINTENANCE PVT System 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 modific...
Page 94 - PVT Drying; Move the vehicle out of the
91 MAINTENANCE PVT System PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out of the water. 2. Remove the PVT drain plug. Use a 17 mm wrench, a flat screw-driver, or the s...
Page 95 - Battery
92 MAINTENANCE Battery Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last. Bat...
Page 96 - Battery Removal; Place the transmission in
93 MAINTENANCE Battery Battery Removal 1. Place the transmission in gear. 2. Lock the parking brake. 3. Open the front cover. 4. Disconnect the battery hold-down strap. 5. On conventional batteries, remove the battery vent tube. 6. Disconnect the black (negative) battery cable first. 7. Disconnect t...
Page 97 - Battery Installation; Ensure that the battery is fully charged.
94 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 96 before installing the battery. 1. Ensure that the battery ...
Page 98 - Battery Storage; for the part numbers
95 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 99 - fully charged
96 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 93. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as neede...
Page 100 - State of
97 MAINTENANCE Battery Battery Charging (Sealed Battery) 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 3 mos. ...
Page 101 - Cleaning and Storage; Washing the Vehicle; and the lower parts last.; Washing Tips
98 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. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden ho...
Page 102 - Polishing the Vehicle; Polishing Tips; • Avoid the use of automotive products, some of which can scratch the
99 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• Tra...
Page 103 - Wash chrome wheels frequently. Use a mild detergent. Never use; Removing Corrosion
100 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscept...
Page 104 - Storage Tips; Clean the Exterior; disperse through the fuel in the tank and carburetor.; Oil and Filter
101 MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period. Clean the Exterior Make any necessary repairs and clean the vehicle as...
Page 105 - Fluid Levels; Treat the fuel system with Polaris Carbon Clean. See page 101.
102 MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Change fluids as recommended in the Periodic Maintenance Chart beginning on page 60.• Demand drive unit (front gearcase)• Transmission• Brake fluid (change every two years and any time the fluid looks dark or co...
Page 106 - Inspect and Lubricate; See pages 95-96 for storage and charging procedures.; Accessories
103 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 60. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers Set the ti...
Page 107 - Transporting the Vehicle; Follow these procedures when transporting the vehicle.
104 MAINTENANCE Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in gear. 3. Lock the parking brake. 4. Turn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to prevent loss during transportin...
Page 108 - ADJUSTMENTS; Camber and Caster; The camber and caster are non-adjustable.; Spring Adjustments; Accessory springs are available through your Polaris dealer.
105 ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Spring Adjustments The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Always adjust both sides equally. Accessory spring...
Page 109 - Handlebars; The handlebars can be adjusted for rider preference.
106 ADJUSTMENTS Handlebars The handlebars can be adjusted for rider preference. WARNING! Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or de...
Page 110 - Carburetor; Carburetor/Engine Idle RPM Adjustment
107 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 111 - Throttle Cable Freeplay; Adjust throttle cable freeplay at the handlebar.
108 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 112 - POLARIS PRODUCTS; Part
109 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 113 - TROUBLESHOOTING; Possible Cause
110 TROUBLESHOOTING Drive Belt Wear/Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range (if equipped). Starting out going up a steep incline Use low range (if equipped) or turn around using the K-turn (see page 52). Driving at low RPM or ground speed (3-7 M...
Page 114 - Engine Doesn't Turn Over
111 TROUBLESHOOTING Engine Doesn't Turn Over Engine Turns Over, Fails to Start Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connec...
Page 115 - Engine Pings or Knocks
112 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 Idle set too...
Page 116 - Engine Stops or Loses Power
113 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 Overuse of choke Insp...
Page 117 - SPECIFICATIONS
114 SPECIFICATIONS * Based on EU Directive 76/432/EC Sportsman 300 Maximum Weight Capacity 385 lbs. (175 kg) (includes weight of opera-tor, cargo and accessories) Dry Weight 550 lbs. (250 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) Transmission Oil 20.3 oz. (600 ml) Demand D...
Page 118 - Jetting Chart
115 SPECIFICATIONS Jetting Chart Clutching Chart Sportsman 300 Drive Ratio, Front 3.6:1 Drive Ratio, Final 15.18:1 Tires/Pressure, Standard models Front 22x7-12 / 5 psi (34.5 KPa)Rear 22x10-12 / 5 psi (34.5 KPa) Tires/Pressure, LE models Front 23x7-12 / 5 psi (34.5 KPa)Rear 23x10-12 / 5 psi (34.5 KP...
Page 119 - WARRANTY; LIMITED WARRANTY
116 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 121 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
118 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 122 - Exported Vehicles; How to Get Service
119 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 123 - Notice
120 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 125 - MAINTENANCE LOG
122 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