Page 2 - 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 - Improper vehicle use can result in SEVERE INJURY or DEATH.; FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer,call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy 55Medina, MN 55340Phone 1-888-704-5290Part No. 9922237 Rev 02Printed in USA WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL I...
Page 5 - 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 se...
Page 7 - TABLE OF CONTENTS
3 TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7Features and Controls . . . . . . . . . . . . . . . . . . . 26Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Emis...
Page 8 - INTRODUCTION; CAUTION; NOTICE
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 hazar...
Page 10 - Vehicle Identification Numbers; spaces provided. Remove the spare key and store it in a safe place. An
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 11 - SAFETY; Safety Training; encourages you and any family members who will be riding the ATV to; in the ATV; for a fee. Call ATV Enrollment Express at; FOR MORE INFORMATION ABOUT ATV SAFETY in the United
7 SAFETY Safety Training ATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the ATV to take a training course.If you purchased a new Polaris ATV in the United States, your dealer provided instruction to you about the authorize...
Page 12 - 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 13 - Eye Protection; Do not depend on eyeglasses or sunglasses for eye protection. When-; Gloves; Always wear long sleeves and long pants to protect arms and legs.; 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 marki...
Page 14 - 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 15 - Handling Gasoline
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 16 - 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 17 - 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 18 - Physical Control of the ATV
14 SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other mo...
Page 19 - Improper Hill Climbing
15 SAFETY Safety Warnings Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 54. Descending Hills Improperly Improperly descending a hill could cause loss of control or...
Page 20 - Stalling While Climbing a Hill; Operating on Steep Hills
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: • Lean forward to keep body weight uphill. A passenger sho...
Page 21 - 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 until you've learned ...
Page 22 - Improper Tire Maintenance
18 SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident.Always use the size and type of tires specified for your ATV.Always maintain proper tire pressure as described in the owner's ma...
Page 23 - Operating Through Deep Water
19 SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or overturn.Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended...
Page 24 - Operating on Frozen Bodies of
20 SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice.Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather co...
Page 25 - 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 26 - Safety Labels and Locations; tact your Polaris dealer to purchase a replacement. Replacement
22 SAFETY Safety Labels 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 d...
Page 27 - General Warning/Discretionary Warning
23 SAFETY Safety Labels and Locations General Warning/Discretionary Warning WARNINGImproper ATV use can result in SEVERE INJURY or DEATHALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGERNEVER USE ON PUBLIC ROADSNEVER CARRY MORE THAN 1 PASSENGERNEVER USE WITH DRUGS OR ALCOHOL ...
Page 28 - Passenger Safety Warning; Tire Pressure/Load Warning
24 SAFETY Safety Labels and Locations Passenger Safety Warning WARNINGPASSENGER SAFETYTo reduce the risk of SEVERE INJURY or DEATHNEVER CARRY MORE THAN ONE PASSENGERNEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand hol...
Page 29 - Rack Warning; Reverse Override Warning/AWD Caution
25 SAFETY Safety Labels and Locations Rack Warning WARNINGDO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg) 7172572 Clutch Cover Warning WARNING• Movin...
Page 30 - FEATURES AND CONTROLS; Switches; Mode/Reverse Override 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, depress the override switch. WARNING! Activating the override switch while the throttle is open can cause loss of control, which m...
Page 31 - Engine Stop Switch; OFF
27 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. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, i...
Page 32 - Throttle Lever
28 FEATURES AND CONTROLS Throttle Lever Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.Failure to...
Page 33 - Brake Lever
29 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 34 - Master Cylinder/Brake Fluid
30 FEATURES AND CONTROLS Master Cylinder/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, m...
Page 35 - Parking Brake; Locking the Parking Brake
31 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 36 - reduce; Brake Fluid Level
32 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 37 - Automatic Transmission Gear Selector; The transmission gear selector is; PARK and lock the parking brake.; Belt Life; Choke; The fuel valve is located under the
33 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: ParkTo shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE:...
Page 38 - Passenger Seat; If the lock-out is not; Fuel Filter; Do not use fuel with etha-
34 FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat is installed and securely latched before operating with a passenger. Test the seat latch by attempting to pull the seat upward. If the lock-out is not working properly, do not allow a passenger to ride the vehicle. See your ...
Page 39 - Engaging AWD
35 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; for additional information.
36 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.The instrument cluster measures distance in mi...
Page 41 - Rider Information Center
37 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. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument...
Page 42 - Standard Modes
38 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 26. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer reco...
Page 43 - Diagnostic Mode; To exit the diagnostic mode, turn the key switch off and on. Any move-
39 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 44 - View this screen to check battery voltage level.; Tachometer Screen; View the tachometer to check engine speed.; AWD Diagnostic Screen; tional purposes only. Please see your dealer for all major repairs.; Gear Circuit Diagnostic Screen; only. Please see your dealer for all major repairs.; Programmable service interval; When the hours of engine operation equal the programmed service
40 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 45 - hold; Miles/Kilometers toggle
41 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 46 - OPERATION
42 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 47 - Engine and Drivetrain Break-in
43 OPERATION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 34. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 72. Add oil if necessary to maintain the level between the safe and add ma...
Page 48 - ATV before each use to make sure it's in safe operating condition.; Item
44 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 Passenger seat latch Ensure latch is s...
Page 49 - Safe Operation Practices
45 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. Engine exhaust ...
Page 50 - Know Your Riding Area/Tread Lightly; terrain, avoid littering, and always stay on the designated trails.; Trail Etiquette; Always practice good etiquette when riding. Allow a safe distance
46 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...
Page 51 - Starting the Engine; choke can cause the spark plug to become wet fouled.
47 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 PARK.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 engag...
Page 52 - Cold Weather Operation
48 OPERATION Starting the Engine 11. 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 53 - Driving Procedures; brakes on level surfaces.
49 OPERATION Driving Procedures 1. Wear protective riding gear. See page 8.2. Perform the pre-ride inspection. See page 44.3. Place the transmission in PARK.4. Lock the parking brake.5. Mount the vehicle from the left side.6. Sit upright with both feet on the footrests and both hands on the handleba...
Page 54 - Driving with a Passenger
50 OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfort- ably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driving...
Page 56 - Turning the Vehicle
52 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 outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.1. Slow down.2. Never...
Page 57 - Driving on Slippery Surfaces; Never apply the brakes during a skid. Correct a skid by turning the
53 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 whe...
Page 58 - Driving Uphill; throttle suddenly could cause the ATV to flip over backwards.
54 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 (15 ° maximum). 3. Always check the...
Page 59 - unavoidable
55 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. Avo...
Page 61 - ger should not remount until the vehicle returns to firm, level
57 OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill.2. Leave the transmission in forward and shut off the engine.3. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill s...
Page 62 - Driving Downhill; descend a hill with the transmission in neutral.
58 OPERATION Driving Downhill When driving downhill, follow these precautions:1. Avoid steep hills (15 ° maximum). 2. Always check the terrain carefully before descending a hill.3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 4....
Page 63 - Driving Through Water; If it’s unavoidable to enter water deeper than the footrest level:
59 OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:1. Determine water depths and current before entering water. 2. Choose a crossing where both banks have gr...
Page 64 - Driving Over Obstacles; ards such as logs, rocks and low hanging branches.
60 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 us...
Page 65 - Driving in Reverse; that a passenger can obstruct your view.
61 OPERATION Driving in Reverse Follow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 2. Always avoid backing downhill.3. Back slowly.4. Apply the brakes lightly for stopping. 5. Avoid turning ...
Page 66 - Parking on an Incline
62 OPERATION Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:1. Stop the engine.2. Place the transmission in PARK.3. Lock the parking brake.4. Always block the rear wheels on the downhill side.5. Turn the fuel valve off.
Page 67 - Hauling Cargo
63 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:Never carry cargo on the rear rack ...
Page 69 - Towing Loads; Always attach a towed load to the hitch point. Remove the hitch from
65 OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.• The combination of rear rack cargo weight and tongue weight must not exceed...
Page 70 - EMISSION CONTROL SYSTEMS; Noise Emission Control System; Do not modify the engine, intake or exhaust components, as doing so; Crankcase Emission Control System; are forced back to the combustion chamber by the intake system. All; Exhaust Emission Control System; operator perform. Any other adjustments should be performed by an; Electromagnetic Interference
66 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 71 - MAINTENANCE; Periodic Maintenance Chart; serviced more frequently.; Severe Use Definition; cause or see your dealer.
67 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 part...
Page 72 - Maintenance Chart Key; Emission-related service
68 MAINTENANCE Periodic Maintenance Chart Improperly performing the procedures marked with a Q 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 75 - Lubrication Guide
71 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 67. Items not listed in the chart should be lubricated at the General Lubrication interval.The a-arms and upper control arms are lubricated at the facto...
Page 76 - Engine Oil; Oil Recommendations; ent temperatures from -40
72 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 77 - Oil Level
73 MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the left side of the ATV. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or mois- ture collecting in the crankcase. If the oil level is over the full/safe mark, change...
Page 78 - Oil and Filter Change
74 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 67.1. Position the vehicle on a level surface.2. Start the engine. Allow it to idle for two to three minutes. 3. Stop the engine.4. Clean the...
Page 79 - Prime the oil pump using the procedure on page 76.
75 MAINTENANCE Engine Oil Oil and Filter Change 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the filter seal...
Page 80 - Oil Pump Priming
76 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 t...
Page 81 - Transmission Oil; use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page; Transmission Oil Level; Position the vehicle on a level
77 MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 67. 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 82 - Transmission Oil Change; the oil to drain completely.
78 MAINTENANCE Transmission Oil Transmission Oil Change 1. Remove the fill plug.2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. (27-34 Nm). 5. Add 32 oz. (948 ml) of the recommended ...
Page 83 - Demand Drive Capacity
79 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 67. We rec- ommend the use of Demand Drive Plus Fluid. Use of other fluids may result in improper operation of components....
Page 84 - Fluid Level; level to the bottom of the fill hole threads.; Fluid Change; fluid level at the bottom of the fill hole threads.
80 MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque...
Page 85 - Cooling System; and ready to use. Do not dilute with water. See page 126 for the part
81 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 86 - Recovery Bottle Coolant; The recovery bottle is located on
82 MAINTENANCE Cooling System Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle.1. Remove the left side panel. See page 86. 2. Maintain the coolant level between the minimum and maximum marks on the bot- tle (when the fluid is cool). 3. Add coolant as needed. Rec...
Page 87 - Radiator Coolant
83 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 drai...
Page 88 - Brakes; Hand Brake
84 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 89 - Toe Alignment
85 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 90 - Steering Assembly
86 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 ne...
Page 91 - Tires; Tire Tread Depth; Always replace tires; Front Wheel Hub Tightening
87 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 92 - Wheel Installation; and rotation arrows on the tire pointing toward forward rotation.; Wheel Nut Torque Specifications; Nut Type; Cast Aluminum
88 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 ve...
Page 93 - Air Filter
89 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-filte...
Page 95 - Fuse Replacement; Fuse
91 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Spare fuses are provided in a com- partment on the top of the access door.1. Open the front box cover and pull open the access door. 2. Remove the suspe...
Page 96 - Lights; make sure lights are adjusted properly for best visibility.; Headlight Lamp Replacement; shorten the life of the lamp. If fingers do touch a lamp, clean it with; Unplug the headlamp from the wiring harness. Be sure to pull on the
92 MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean head- lights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headligh...
Page 97 - High Beam Adjustment
93 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
94 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 h...
Page 99 - Lower Headlamp Replacement
95 MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight harness counter-clockwise 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; Spark Plug Inspection; spark plug counter-clockwise to remove it.; Plug Condition
96 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 124 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 u...
Page 101 - Normal Spark Plug; end. There may be a carbon layer over the entire nose. Generally, the
97 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.The tip should not b...
Page 102 - Camber and Caster; The rear shock absorber spring is
98 MAINTENANCE Camber and Caster The camber and caster are non-adjust- able. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension. Tip: Accessory springs are available through your Polaris dealer....
Page 103 - Handlebars
99 MAINTENANCE 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 dea...
Page 104 - Carburetor; engine air/fuel mixture becomes overly rich and the engine loses; Carburetor/Engine Idle RPM Adjustment; warm up for approximately five
100 MAINTENANCE 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 105 - Throttle Cable Freeplay
101 MAINTENANCE 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 th...
Page 106 - Vehicle Immersion
102 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 bel...
Page 107 - Spark Arrestor; plug from the bottom of the
103 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 108 - PVT System
104 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 109 - force exerted on the movable drive sheave by the flyweights also
105 MAINTENANCE PVT System The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to th...
Page 110 - When To Use Low Range and High Range; stall the drain plug.; 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 the...
Page 111 - Battery; cleaning solution or tap water into a conventional battery.
107 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. Ba...
Page 112 - Battery Removal; battery sideways, which could spill electrolyte.
108 MAINTENANCE Battery Battery Removal 1. Remove 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 out of t...
Page 113 - Battery Installation; teries do not have a vent tube). The vent tube must be free of
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 114 - Battery Storage
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 115 - 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 116 - State of
112 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 117 - Cleaning and Storage; Washing the Vehicle; but it can also extend the life of various components.; 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. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden h...
Page 118 - Polishing the Vehicle; instructions on the container.; 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• R...
Page 119 - 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. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more suscep...
Page 120 - Storage Tips; Clean the Exterior; Follow the instructions on the container for the recommended; Oil and Filter
116 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 121 - Fluid Levels
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 67.• Demand drive unit (front gearcase)• Rear gearcase (if equipped)• Transmission• Brake fluid (change every two years and...
Page 122 - Inspect and Lubricate; in the Periodic Maintenance Chart beginning on page 67.; See pages 110-111 for storage and charging procedures.; Accessories; install accessories that are approved for ATV use. Please see your
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 67. Battery Storage See pages 110-111 for storage and charging procedures. Storage Area/Covers Set the ...
Page 123 - 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 and oil cap. 5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or ...
Page 124 - TROUBLESHOOTING; Possible Cause
120 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 56). Driving at low RPM or ground speed (3-7 MPH) Drive at ...
Page 125 - Engine Doesn't Turn Over
121 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 126 - Engine Pings or Knocks
122 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 127 - Engine Stops or Loses Power
123 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 128 - SPECIFICATIONS
124 SPECIFICATIONS * Based on EU Directive 76/432/EC SPORTSMAN Touring 500 HO Maximum Weight Capacity 705 lbs. (320 kg) (includes operator, passenger, cargo, accessories) Dry Weight 770 lbs. (349 kg) (base model) Front Rack/Storage Box Capacity 90 lbs. (41 kg)Rear Rack Capacity 180 lbs. (82 kg) Rece...
Page 129 - Jetting Chart
125 SPECIFICATIONS Clutching (EBS Models) *EBS models require no helix/spring adjustment Jetting Chart SPORTSMAN Touring 500 HO Driving System Type Automatic PVT (Polaris Variable Transmission) Front Suspension MacPherson strut with 8.2" (21 cm) travel Rear Suspension Progressive rate with 8.75&...
Page 130 - POLARIS PRODUCTS; Description
126 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 131 - DECLARATION OF CONFORMITY
127 DECLARATION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500 We, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles. PRODUCT IDENTIFIC...
Page 132 - WARRANTY; LIMITED WARRANTY; REGISTRATION
128 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 134 - LIMITATIONS OF WARRANTIES AND REMEDIES
130 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, te...
Page 135 - HOW TO OBTAIN WARRANTY SERVICE; SPARK ARRESTOR
131 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 state...
Page 136 - Exported Vehicles; How to Get Service
132 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 ex...
Page 137 - Notice
133 WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen, to be kept and used outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is reg...
Page 140 - MAINTENANCE LOG; log of maintenance and services performed.
136 MAINTENANCE LOG Present this section of your manual to your dealer each time your vehi- cle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed. DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
Page 142 - INDEX
138 INDEX A Accessories . . . . . . . . . . . . . . . . . . 118 Air Filter . . . . . . . . . . . . . . . . . . . . . 89 All Wheel Drive System . . . . . . . . . 35 Auxiliary Foot Brake . . . . . . . . . . . . 84 AWD Switch . . . . . . . . . . . . . . . 27, 35 B Battery . . . . . . . . . . . . . . . ...