Page 2 - PRINTED IN THE USA; WARNING; Improper vehicle use can result in SEVERE INJURY or DEATH.
Part No. 9919515 Rev 03 PRINTED IN THE USA WARNING Improper vehicle use can result in SEVERE INJURY or DEATH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL ...
Page 3 - to the owner’s manual on the next page. If you cannot locate this card,; The engine exhaust from this
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. The engine exhaust from this product contains chemicals known to cause cancer, birth def...
Page 6 - WELCOME; Polaris Recreational and Utility Vehicles; RANGER
3 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. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrain vehicles (ATVs) S Watercraft S Victory motorcy...
Page 8 - TABLE OF CONTENTS
5 TABLE OF CONTENTS WELCOME 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VEHICLE IDENTIFICATION NUMBERS 6 . . . . . . . . . . . . . . . SAFETY 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FEATURES AND CONTROLS 33 . . . . ....
Page 9 - VEHICLE IDENTIFICATION NUMBERS; Record your ATV’s identification numbers and key number in the
6 VEHICLE IDENTIFICATION NUMBERS Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition swi...
Page 10 - SAFETY; Operator Safety; vehicle handles differently than other vehicles, such as; Age Restrictions
7 SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in serious injury or death.A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can o...
Page 11 - The following signal words and symbols appear throughout this; safety alert symbol; safety alert warning; safety alert caution; CAUTION; caution
8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your ATV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual, al...
Page 12 - Serious injury or death can result if you do not follow these; Take a training
9 SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and follow the operating procedures described. S Never operate an ...
Page 14 - FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-; Equipment Modifications; The addition of certain accessories, including (but not limited
11 SAFETY Operator Safety S Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads. S Always check for obstacles or people behind the ATV before operat- ing in reverse. When it’s safe to...
Page 15 - not know how to operate the ATV properly in different situations; abilities, or judgment needed to operate an ATV safely and could
12 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this ATV without proper instruction.WHAT CAN HAPPENThe risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain.HOW TO AVOID THE HAZARDB...
Page 19 - visibility and operating conditions, and your experience.; chance of an accident, including
16 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating the ATV at excessive speeds.WHAT CAN HAPPENExcessive speed increases the operator’s chance of losing control of the ATV, which can result in an accident.HOW TO AVOID THE HAZARDAlways operate the ATV at a speed that’s proper for the terrain,...
Page 20 - schedules described in the owner’s manual.; come into contact with the rear wheels and lead to accident or
17 SAFETY Operator Safety WARNING POTENTIAL HAZARDFailure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPENPoor maintenance increases the possibility of an accident or equipment damage.HOW TO AVOID THE HAZARDAlways inspect your ATV before each use to make sure ...
Page 22 - Never operate the ATV on hills steeper than 25
19 SAFETY Operator Safety WARNING POTENTIAL HAZARDTurning improperly.WHAT CAN HAPPENImproper turns could cause loss of control and lead to a collision or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for turning as described in the owner’s manual.Practice turning at slow speeds bef...
Page 23 - cause loss of control or
20 SAFETY Operator Safety WARNING POTENTIAL HAZARDClimbing hills improperly.WHAT CAN HAPPENImproper hill climbing could cause loss of control or overturn.HOW TO AVOID THE HAZARDAlways follow proper procedures for climbing hills as described in the owner’s manual.Always check the terrain carefully be...
Page 25 - as hills could cause loss of
22 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly crossing hills and turning on hills.WHAT CAN HAPPENImproperly crossing or turning as hills could cause loss of control or overturn.HOW TO AVOID THE HAZARDNever attempt to turn the ATV around on any hill until you’ve mastered the turning te...
Page 26 - improperly dismounting while
23 SAFETY Operator Safety WARNING POTENTIAL HAZARDStalling, rolling backwards or improperly dismounting while climbing a hill.WHAT CAN HAPPENThe vehicle could overturn.HOW TO AVOID THE HAZARDMaintain steady speed when climbing a hill.If all forward speed is lost:Keep your weight uphill.Apply the fro...
Page 27 - trees when possible. If unavoidable, use extreme caution and; caution to reduce the chance of skidding or sliding out of control.
24 SAFETY Operator Safety WARNING POTENTIAL HAZARDImproperly operating over obstacles.WHAT CAN HAPPENOperating over obstacles could cause loss of control or overturn.HOW TO AVOID THE HAZARDBefore operating in a new area, check for obstacles.Avoid operating over large obstacles such as rocks and fall...
Page 29 - accessories. All parts and accessories added to the vehicle must
26 SAFETY Operator Safety WARNING POTENTIAL HAZARDOperating this ATV with improper tires, or with improper or uneven tire pressure.WHAT CAN HAPPENUse of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident.HOW TO AVOID THE HAZARDAlway...
Page 31 - Safety Decals and Locations; Warning decals have been placed on the ATV for your protection.
28 SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions on each decal carefully. If a decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by ...
Page 34 - NO STEP
31 SAFETY Safety Decals and Locations ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner ’s Manual. 7079780 MANUFACTURED BY: POLARIS IND, INC. DATE: VIN: THIS VEHICLE IS AN ALL TERRAIN VEHICLE A...
Page 35 - Safe Riding Gear
32 SAFETY Safe Riding Gear Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury. 1. Helmet Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injur...
Page 36 - FEATURES AND CONTROLS; Electrical Switches; mode of the speedometer (if equipped). To gain additional power
33 FEATURES AND CONTROLS Electrical Switches WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Speedo Mode/Override Switch (1) (Reverse Speed Limiter) - Thi...
Page 38 - Throttle Lever
35 FEATURES AND CONTROLS WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls, which could cause an accident and lead to severe injury or death.Always contact your dealer for service repairs if throttle problems arise.Failure to check or maintain proper oper...
Page 39 - Brake Lever; Operating the ATV with a spongy brake lever can result in loss of
36 FEATURES AND CONTROLS Brake Lever The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear brakes are hydraulically activated disc type brakes that are activated by only one lever. WARNING Operating the ATV with a spongy brake lever can resul...
Page 40 - Brake Fluid; of the master cylinder. This “eye” will appear dark when the fluid
37 FEATURES AND CONTROLS Brake Fluid Check the brake fluid level in the master cylinder before each use of the ATV. The master cylinder (2) is located on the left handlebar.The fluid level can be seen through an indicator window (3) on the top of the master cylinder. This “eye” will appear dark when...
Page 41 - Parking Brake; Operating the ATV while the parking brake is engaged could; Locking the Parking Brake; Important Safeguards
38 FEATURES AND CONTROLS Parking Brake WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. Locking the Parking Brake 1. Squeeze and release the brake lever (1) ...
Page 42 - Auxiliary Brake; Aggressively applying the rear brake when backing down a hill; reduce
39 FEATURES AND CONTROLS Auxiliary Brake WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover, which could result in serious injury or death. If the rear brake is applied aggressively while moving forward, the rear wheels may skid and slide sideways, causing l...
Page 43 - Choke; The fuel valve (1) is located on the left side; There’s about a 7 to 10 mile; Always return valve to the ON; Fuel Tank; operation, or annually. Do not attempt to clean the fuel filter.
40 FEATURES AND CONTROLS Choke The choke assists in starting a cold engine. Refer to the engine starting procedure on page 53 for correct choke and throttle settings during starting. Fuel Valve The fuel valve (1) is located on the left side panel. It has three positions:OFF: For vehicle storage and ...
Page 44 - Fuel Safety
41 FEATURES AND CONTROLS Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well ventilated area. S Never fill a gas container while it’s ...
Page 45 - Automatic Transmission Gear Selector; is located on the right side of the; Shifting gears with the engine speed above idle or while the; Belt Life; better mobility and to prevent damage to the belt.
42 FEATURES AND CONTROLS Automatic Transmission Gear Selector The transmission gear selector (1) is located on the right side of the vehicle.H: High Gear L: Low GearN: NeutralR: ReverseP: ParkTo shift into HIGH or PARK, you must first apply the auxiliary brake to activate the high/park lock-out mech...
Page 46 - Recoil Starter; Extending the starter rope too far will cause damage to the recoil
43 FEATURES AND CONTROLS Recoil Starter If the battery is weak and cannot start the engine, use of the recoil starter (1) will allow vehicle operation until repairs can be made. The recoil starter is located on the right side of the machine.Polaris 4-cycle engines are equipped with automatic decompr...
Page 47 - The override switch allows activation of AWD in reverse if the; Operating in TURF mode when on sloped, uneven, or loose
44 FEATURES AND CONTROLS All Wheel Drive (AWD) System Polaris 4 wheel drive ATVs are equipped with a unique, AWD system activated by a switch (1) on the right handlebar.When the switch is on 2X4 (center position), the ATV is in two wheel drive at all times and the differential is locked.When the swi...
Page 48 - Engaging the Front Gearcase; The AWD switch may be turned on or off while the vehicle is moving.; Switching to AWD (or from TURF to 2X4) while the rear wheels
45 FEATURES AND CONTROLS All Wheel Drive (AWD) System Engaging the Front Gearcase The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle’s electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the...
Page 49 - Instrument Cluster; speed from the right front wheel. The instrument cluster measures; To prevent damage, wash the ATV by hand or with a garden hose
46 FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV’s s...
Page 50 - Rider Information Center; If the instrument cluster fails to illuminate, a battery; Engine Hour Display Indicator
47 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments 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 instru...
Page 51 - mode
48 FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center has 4 standard modes:Mode 1 - OdometerMode 2 - TripmeterMode 3 - Total Service HoursMode 4 - TachometerThe reverse override button on the left handlebar is also the mode button . NOTE: If using the mode...
Page 52 - Diagnostic Mode; Any movement of the tires will also take the machine out of
49 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.To leave the diagno...
Page 53 - If you scroll past the intended number, hold the button down; OFF
50 FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory...
Page 54 - Excessive heat build-up during the first three hours of operation
51 OPERATION Break-In Period The break-in period for your new Polaris ATV is defined as 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 procedures for a proper break-in. Careful treatme...
Page 55 - If a proper inspection is not done before each use, severe injury
52 OPERATION Pre-Ride Inspection 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. Pre-Ride Checklist Item Remarks See Page Brake system / lever travel Ensure prope...
Page 56 - OPERATION; Starting the Engine; Starting a Cold Engine
53 OPERATION Starting the Engine Starting a Cold Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. CAUTION Operating the vehicle immediately after starting could cause eng...
Page 57 - Starting a Warm Engine
54 OPERATION Starting the Engine Starting a Warm Engine Warm engines do not normally require the use of the choke. Using the choke can cause the spark plug to become wet fouled.1. Position the vehicle on a level surface with the transmission in park. 2. Lock the parking brake, turn the fuel tank val...
Page 58 - Hauling Cargo; and
55 OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: S Never exceed the stated load capacity for this vehicle. S Reduce spee...
Page 59 - Load Distribution; Maximum Towing Capacities
56 OPERATION Hauling Cargo Load Distribution Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights.Cargo weight should be mounted as low as possible. When ope...
Page 60 - Dumping Cargo; Select a level site to dump the cargo box. Do not attempt to dump
57 OPERATION Hauling Cargo Dumping Cargo 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Place the transmission in park and set the parking brake.3. Dismount the vehicle.4. Lower the tailgate. WARNING If cargo weight is placed...
Page 61 - Driving Safely; Driving Procedures; Sit upright with both feet on the footrests and both hands on the
58 OPERATION Driving Safely Driving Procedures 1. Sit upright with both feet on the footrests and both hands on the handlebars. 2. Start the engine and allow it to warm up, then shift the transmission into gear. 3. Check your surroundings and determine your path of travel.4. Release the parking brak...
Page 62 - Making Turns; either 2X4 or 4X4 mode. This means that the wheel on the outside of a; Practice making turns at slow speeds before attempting to; Turning at sharp angles or at excessive speeds can result in
59 OPERATION Driving Safely Making Turns Your Polaris ATV is equipped with a rear differential that functions as a solid rear axle, driving both rear wheels equally when the ATP is in either 2X4 or 4X4 mode. This means that the wheel on the outside of a turn must travel a greater distance than the i...
Page 63 - Driving on Slippery Surfaces; quick, sharp turns which can cause skids.; Severe damage to drive train may occur if the AWD is engaged; Failure to exercise care when operating on slippery surfaces can
60 OPERATION Driving Safely Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:1. Slow down when entering slippery areas.2. Maintain a high level of alertness, reading the trail and avoiding quick...
Page 64 - Driving Uphill; If all forward speed is lost:; terrain. Improper procedure could cause loss of control or
61 OPERATION Driving Safely Driving Uphill Whenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25 _ maximum). 3. Keep both feet on the footrests.4. Transfer your weight forward.5. Proceed at a steady rate of speed and throttle opening. 6. Remain...
Page 65 - Sidehilling; control or vehicle overturn, resulting in severe injury or death.; while keeping your feet on the footrests.; If the vehicle begins to tip, quickly turn the front wheel
62 OPERATION Driving Safely Sidehilling WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Follow proper procedures as outlined in the owner’s manual. Sidehilli...
Page 66 - Driving Downhill; slightly; Excessive speed can cause loss of control and lead to serious
63 OPERATION Driving Safely Driving Downhill Whenever descending a hill, follow these precautions:1. Proceed directly downhill.2. Transfer your weight to the rear of the vehicle.3. Slow down.4. Apply the brakes slightly to aid in slowing. Familiarize yourself with operation of the auxiliary rear bra...
Page 67 - Turning Around on a Hill; Improper hill climbing procedures could cause loss of control or; slowly
64 OPERATION Driving Safely Turning Around on a Hill WARNING Improper hill climbing procedures could cause loss of control or overturn and result in serious injury or death.Avoid climbing steep hills (25 _ maximum). Use extreme caution when operating on hills, and follow proper operating procedures ...
Page 68 - Driving Through Water; Your ATV can operate through water with a maximum recommended
65 OPERATION Driving Safely Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). Follow these procedures when operating through water:1. Determine water depths and current before crossing.2. Choose a crossing where both b...
Page 69 - critical; If water has been ingested into the PVT, follow the procedure; Major engine damage can result if the vehicle is not thoroughly
66 OPERATION Driving Safely Driving Through Water After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 73. The following areas need special attention: engine oil, transmission oil, front and rear gearcases and all grease fittings. NOTE:...
Page 70 - Driving Over Obstacles; for hazards such as logs, rocks and low hanging branches.; Severe injury or death can result if your vehicle comes in contact
67 OPERATION Driving Safely Driving Over Obstacles Be alert! Look ahead and learn to read the terrain. 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. Not all obstacles ar...
Page 71 - Driving in Reverse; apply the brakes
68 OPERATION Driving Safely Driving in Reverse Follow these precautions when operating in reverse:1. Always avoid backing downhill. 2. Back slowly.3. When in reverse, apply the brakes lightly for stopping. 4. Avoid turning at sharp angles in reverse. 5. Never open the throttle suddenly while backing...
Page 72 - Parking on an Incline; Avoid parking on an incline if possible. If it’s unavoidable, follow
69 OPERATION Driving Safely Parking on an Incline Avoid parking on an incline if possible. If it’s unavoidable, follow these precautions:1. Turn the engine off.1. Place the transmission in park.2. Set the parking brake.3. Always block the rear wheels on the downhill side as shown in illustration. 4....
Page 73 - PVT System; When To Use Low Range vs. High Range; Low Range
70 OPERATION 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 the...
Page 74 - PVT Drying; the PVT system. Use the following instructions to dry it out before
71 OPERATION 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 mo...
Page 75 - EMISSION CONTROL SYSTEMS; Noise Emission Control System
72 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with state and local noise level requirements. Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with ...
Page 76 - MAINTENANCE AND LUBRICATION; Accessories; Severe Use Definition; Maintenance Chart Key
73 MAINTENANCE AND LUBRICATION Accessories Auxiliary power outlets provide 12V power for operating accessories such as hand held spot lights. See your Polaris dealer. Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspectio...
Page 77 - Periodic Maintenance Chart
74 MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) J Steering -- Pre-Ride -- Make adjustments as need- ed See Pre Ride Checklist " F...
Page 80 - Lubrication Recommendations; More often under severe use, such as wet or dusty conditions
77 MAINTENANCE AND LUBRICATION Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Items not listed in the chart should be lubricated at the General Lubrication interval. Lubrication Chart Key " More oft...
Page 81 - Periodic Maintenance Record; Use the following chart to record periodic maintenance.
78 MAINTENANCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance. Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks
Page 82 - Engine Oil; Premium 4 Synthetic Oil; Mixing brands or using a non-recommended oil may cause
79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Always change the oil filter whenever changing oil. Premium 4 Synthetic Oil Polaris Premium 4 All Season Synt...
Page 85 - The sealing surfaces on the drain plug and crankcase should; Prime the oil pump using the procedure below; If you do not hear air,
82 MAINTENANCE AND LUBRICATION Lubrication Recommendations Engine Oil Oil and Filter Change (ATP 500) 11. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase. NOTE: The sealing surfaces on the drain plug and crank...
Page 88 - Transmission Oil; Oil Check
85 MAINTENANCE AND LUBRICATION Lubrication Recommendations Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Maintain the oil level 1 5/8” from the top of the fill hole. We recommend the use of Premium AGL ...
Page 89 - Front Gearcase Oil
86 MAINTENANCE AND LUBRICATION Lubrication Recommendations Front Gearcase Oil Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Maintain the oil level 3/4” below the fill plug opening. We recommend the use of Polaris Prem...
Page 90 - Rear Gearcase Oil
87 MAINTENANCE AND LUBRICATION Lubrication Recommendations Rear Gearcase Oil Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 73. Maintain the oil level at the bottom of the fill hole. We recommend the use of Polaris ATV Angl...
Page 91 - Engine Cooling System; Some coolant level drop on new machines is normal, as the
88 MAINTENANCE AND LUBRICATION Engine Cooling System Oil Cooler (ATP 330) The oil cooling system requires little maintenance other than to make sure the cooler is kept free of mud and debris. Change the engine oil as recommended in the maintenance schedule. Cooling System Operation (ATP 500) The eng...
Page 93 - Adjustments; Brakes
90 MAINTENANCE AND LUBRICATION Adjustments Brakes The front brakes are hydraulic disc brakes, activated by moving the brake lever toward the handlebar. These brakes are self-adjusting. WARNING Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs ...
Page 94 - backup for the main brake system. Should the main system fail, the; Since the auxiliary brake is a rear brake only, it will not be as
91 MAINTENANCE AND LUBRICATION Adjustments Auxiliary Brake The auxiliary brake is a hydraulic disc brake. The rear brake system is self-adjusting and requires no maintenance other than periodic checks of the pads for wear.Change the brake pads when they’re worn to 3/64 ″ (.1 cm). Inspect the brake d...
Page 95 - Toe Alignment
92 MAINTENANCE AND LUBRICATION Adjustments WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. Toe Alignment Use the following procedure to check...
Page 96 - Steering Assembly; dealer for service before operating the vehicle.; Camber and Caster; The camber and caster are non-adjustable.; Rear Spring; The rear shock absorber spring is adjusted by; Accessory springs are available
93 MAINTENANCE AND LUBRICATION Adjustments 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. Camber and Caster The camber and caster are non-...
Page 97 - Handlebars; Improper adjustment of the handlebars or incorrect torquing of
94 MAINTENANCE AND LUBRICATION Adjustments Handlebars If desired, 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 lo...
Page 98 - Carburetor; Continuous operation of the engine without proper jetting
95 MAINTENANCE AND LUBRICATION 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 ...
Page 99 - Throttle Cable Freeplay; achieved at the thumb lever.; While adjusting freeplay, be sure to flip the throttle lever back; they touch at the midpoint of the adjuster.
96 MAINTENANCE AND LUBRICATION Adjustments Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar.1. Slide the boots (1) off the inline cable adjuster sleeve (2). Loosen the adjuster locknut (3). 2. Turn the adjuster until 1/16 ″ to 1/8 ″ (.16-.32 cm) freeplay is achieved at th...
Page 100 - Side Panel Removal; Side panel removal may be difficult until the locking tabs and
97 MAINTENANCE AND LUBRICATION Adjustments Side Panel Removal NOTE: Side panel removal may be difficult until the locking tabs and receivers have been snapped and unsnapped a few times. 1. Remove the seat.2. Grasp the rear of the side panel near the rear cab. With a quick and firm motion, pull the p...
Page 101 - Operating your ATV with worn tires, improperly inflated tires,; Wheel Removal; Stop the engine, place the transmission in park and lock the
98 MAINTENANCE AND LUBRICATION Adjustments WARNING 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.Maintain proper tire pressure as described ...
Page 102 - Wheel Installation; Location
99 MAINTENANCE AND LUBRICATION Adjustments WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See yo...
Page 103 - Front Wheel Hub Tightening; component operations. All service must be performed by your; Tire Tread Depth; Always replace tires when tread
100 MAINTENANCE AND LUBRICATION Adjustments Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer. Tire Tread Depth Always replace tires when tread depth is worn to 1/8 ″ (...
Page 104 - Filter Systems; Air Filter; Operation of your vehicle without a breather filter can cause
101 MAINTENANCE AND LUBRICATION Filter Systems Air Filter 1. Remove the seat, release the clips, and remove the air box cover. 2. Loosen the clamp and remove the filter. 3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry. 4. ...
Page 105 - Lights; Poor lighting while driving can result in severe injury or death.
102 MAINTENANCE AND LUBRICATION 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. WARNING Poor lighting while driving can result in severe injury or death. Headlight and tailli...
Page 106 - Lower Headlight Lamp Replacement
103 MAINTENANCE AND LUBRICATION Lights Lower Headlight Lamp Replacement 1. Turn the back of the headlight harness in a counter-clockwise direction to loosen (A). 2. Pull the harness assembly out from the headlight assembly. 3. Remove the headlamp and replace with a new headlamp. 4. Install the new h...
Page 107 - Headlight Housing Replacement; The distance from the headlamp parting line to the end of the
104 MAINTENANCE AND LUBRICATION Lights Headlight Housing Replacement 1. Remove the three screws on the headlight pod.2. Using a small flat-blade screwdriver, push in on the lock tabs through the two small openings at the front of the headlight pod. Lift the pod lightly while depressing the tabs. 3. ...
Page 108 - High Beam Adjustment; Include rider weight on the seat when measuring.
105 MAINTENANCE AND LUBRICATION Lights High Beam Adjustment The headlight beam can be adjusted to any position desired by turning the adjusting knob on the bottom right side of the headlight pod.1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m.) from a wall. ...
Page 109 - Spark Plugs; Spark Plug Removal and Replacement
106 MAINTENANCE AND LUBRICATION Spark Plugs S Use the recommended spark plugs for your model (see SPECIFICATIONS beginning on page 124). S Make sure the electrode gap meets specifications for your model. S Torque spark plugs to 14 ft. lbs. (19 Nm). CAUTION Using non-recommended spark plugs can resul...
Page 110 - Vehicle Immersion; If your vehicle becomes immersed, major engine damage can; Dry the spark plug and reinstall, or replace
107 MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION 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, follo...
Page 111 - Spark Arrestor
108 MAINTENANCE AND LUBRICATION Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.Do not perform service on the spark arrestor while the system is hot. Exhaust system temperatures can reach 1000 ° F. Allow compone...
Page 112 - Recoil Housing; crankcase
109 MAINTENANCE AND LUBRICATION Recoil Housing To prevent possible engine damage, always drain the recoil housing (1) after operating the ATV in very wet conditions. This should also be done before storing the ATV. NOTE: Water will enter the recoil housing if the starter handle is disengaged from th...
Page 113 - Battery; in an explosion and cause serious injury or death. When; Battery Removal; initial use. Using a new battery that has not been fully charged can
110 MAINTENANCE AND LUBRICATION Battery WARNING 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 negativ...
Page 114 - Battery Storage; The following battery charging instructions apply only to the
111 MAINTENANCE AND LUBRICATION 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 re...
Page 115 - Battery Charging; Always verify battery condition before and 1-2 hours after the
112 MAINTENANCE AND LUBRICATION Battery Battery Charging 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 116 - Cleaning and Storage; Cleaning the ATV
113 MAINTENANCE AND LUBRICATION Cleaning and Storage See page 119 for the part numbers of Polaris products. Cleaning the ATV Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components. With a few precautions, your ATV can be cleaned much like an...
Page 117 - Storage Tips; Starting the engine during the storage period will disturb the
114 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 119 for the part numbers of Polaris products. CAUTION 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....
Page 118 - Fog the Engine
115 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips See page 119 for the part numbers of Polaris products. Fog the Engine Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. To access the plug hole, use a section of clear 1/4” hose and a small plastic ...
Page 119 - before placing it in storage. See page 111 for instructions.; Do not use plastic or coated materials. They do not allow; Transporting the ATV; using suitable straps or rope.
116 MAINTENANCE AND LUBRICATION Cleaning and Storage Storage Tips Battery Storage Remove the battery from the vehicle and ensure that it’s fully charged before placing it in storage. See page 111 for instructions. Engine Anti-Freeze Test engine coolant strength and change if necessary. Coolant shoul...
Page 120 - Removing Corrosion
117 MAINTENANCE AND LUBRICATION Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a “like new” appearance for many years.1. Wash chrome rims frequently. Use a mild detergent to remove any salt, dirt, mud ...
Page 122 - POLARIS PRODUCTS
119 POLARIS PRODUCTS Part No. Description Engine Lubricant 2870791 Fogging Oil (12 oz. Aerosol) 2871281 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt.) 2871844 Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal.) Gearcase / Transmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lube (q...
Page 123 - TROUBLESHOOTING; Drive Belt and Cover Problems; Possible Cause
120 TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the ATV onto a pickup or tall trailer in high range. Shift transmission to low range during loading of the ATV to prevent belt burning. Starting out going up a steep incline. When starting out on an incline, use low ra...
Page 124 - solutions using the following charts.; Engine Doesn’t Turn Over
121 TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. Engine Doesn’t Turn Over Possible Cause Solution Tripped circuit breaker Reset the breaker Low battery voltage Recharge battery to 12.5 VDC Loose battery connections Check a...
Page 125 - Engine Backfires
122 TROUBLESHOOTING Engine Backfires Possible Cause Solution Weak spark from spark plugs Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Incorrectly installed spark plug wires See you...
Page 126 - Engine Stops or Loses Power
123 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Solution Out of fuel Turn fuel valve to reserve, refuel Kinked or plugged fuel vent line Inspect and replace Water present in fuel Replace with new fuel Overuse of choke Inspect, clean and/or replace spark plugs Fouled or defective spark...
Page 127 - SPECIFICATIONS
124 SPECIFICATIONS ATP 330 4X4 Gross Vehicle Weight 1300 lbs./590 kg Fuel Capacity 3.25 gal./12.3 l Towing Rating 1000 lbs./454 kg Unbraked Trailer Towing Capacity* 1585 lbs./719 kg Hitch Tongue Capacity 100 lbs./45.4 kg (rear box capacity and tongue weight not to exceed 250 lbs./113 kg) Front Rack ...
Page 131 - WARRANTY; LIMITED WARRANTY
128 WARRANTY LIMITED WARRANTY Polaris Industries 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 de- fects in material or workmanship. This warranty covers the parts and labor charges for repair or repla...
Page 132 - LIMITATIONS OF WARRANTIES AND REMEDIES; HOW TO OBTAIN WARRANTY SERVICE; Lubricants
129 WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRAN- TY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES ...
Page 133 - Exported Vehicles; How to Get Service
130 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION.This policy does not apply to vehicles that have received authorization for export...
Page 134 - California Emission Control Warranty Statement; Your Warranty Rights and Obligations; Limited Warranty
131 WARRANTY California Emission Control Warranty Statement Your Warranty Rights and Obligations The California Air Resources Board and Polaris Industries Inc., 2100 Highway 55, Medina, Minnesota 55340 (herein “POLARIS”) are pleased to explain the emission control system warranty on your 2004 and la...
Page 135 - Warranty Period
132 WARRANTY California Emission Control Warranty Statement Warranty Period This warranty period begins on the date, which the LSI engine is delivered, to the origi- nal retail purchaser and ends two years after that date. During this two year period POLARIS warrants to the original retail purchaser...
Page 136 - What is Not Covered Under This Warranty; Maintenance Schedule
133 WARRANTY California Emission Control Warranty Statement What is Not Covered Under This Warranty This warranty does not cover any emission-related part, which malfunctions, fails, or is damaged due to alterations and/or modifications such as changing, adding, or removing parts. When the LSI engin...
Page 138 - Repair and Replacement of Emission-Related Parts; How to File a Warranty Claim/Where to Get Warranty Service
135 WARRANTY California Emission Control Warranty Statement Repair and Replacement of Emission-Related Parts It is recommended that only LSI engine replacement parts, which have been authorized and approved by POLARIS, should be used in the performance of any warranty maintenance or repairs of emiss...
Page 139 - INDEX
136 INDEX A Accessories 73 . . . . . . . . . . . . . . . . . . . . . . Adjustments 90-100 . . . . . . . . . . . . . . . . . Age Restrictions 7 . . . . . . . . . . . . . . . . . . . Air Filter 101 . . . . . . . . . . . . . . . . . . . . . . . All Wheel Drive 44-45 . . . . . . . . . . . . . . . Auxili...