Polaris 922362 manuale d’uso

Owner's Manual for Maintenance and Safety Read this manual carefully . It contains important safety information. This is an adult vehicle only . Operation is prohibited for those under 16 years of age. P antone 426 C HA WKEYE 2X4[...]

The text is printed on 100% recycled with 40% post-consumer waste (PCW) .[...]

P antone 426 C For your nearest Polaris dealer , visit www .polarisindustries.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 U.S.A. Part No. 9922362 Rev 0 2 Printed in U.S.A. W ARNING Improper vehicle use can r esult in SEVERE INJUR Y or DEA TH. NEVER operate: S without proper training or instruction. S at speeds too fast for your skills o[...]

1 WELCOME Thank you for purcha sing a Polaris vehicle, and welcome to our world- wide family of Polaris owners. W e proudly produce an ex citing line of utility and recreati onal products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ® Always follow the instructions and recommendations in[...]

2 POLARIS, THE W A Y OUT and HA WKEYE are register ed trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication. Due to constant improvements in the design and quality of production components, some minor discrep- [...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . 20 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Emission Control Systems . . . . . . . . . . . . [...]

4[...]

5 INTRODUCTION The following signal words and symbol s appear throughout this man ual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol indicates a potential personal injury hazard. W ARNING A W ARNING indicates a hazardous s[...]

6 INTRODUCTION Failure to follow the warnings in this manu al can result in serious injury or death. This Polaris vehicl e is not a toy and can b e hazardous to operate. A collision or rollover can occur quickly , e ven during routine maneuvers, if you fail to take proper precautions. Read and understand your owner's manu al and all warnings b[...]

7 INTRODUCTION V ehicle Identification Numbers Record your vehicle's identificatio n numbers and key numb er 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 k ey number) and mating it wi th one of your existing keys. The ignition switc[...]

8 SAFETY Operator Safety Serious injury or death can result if you do not follow the instructions and procedures listed here a nd th roughout this manual. Read and understand all warnings, cautions and operating procedu res in this manual and on the safety labels before operatin g this vehicle. Never operate this vehicle without proper instruction.[...]

9 SAFETY Operator Safety Always wear an approved helmet that fits properly . Wear eye protection (goggles or face shield), gloves, boots, long sleeves and lon g pant s. Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. T ravel and turn at speeds appropriate for the terrain, visibil ity , opera[...]

10 SAFETY Operator Safety Always inspect your vehicle before each use to verify th at it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 35. Keep both hands on the handlebars. Keep both feet on the footrests. Always travel slowly when operating on unfamiliar terrain. U se extra [...]

11 SAFETY Operator Safety Always follow the pro cedures outlined in this manual for turning. Never turn shar ply at excessive speeds, which can lead to vehicle overturn. Se e page 39. If this vehicle has b een involved in an accident, always have an authorized Polari s dealer inspect the entire vehicle for possible damage, includin g (but not limit[...]

12 SAFETY Operator Safety Always follow the pro cedures outlined in this manual for brakin g if you stall or roll backwards while cli mbing a hill. Never back down a hill. See page 44. Always follow the procedures outlined in this manual for operating over obstacles. See p age 48. Always follow the procedure s outlined in this manual for operating [...]

13 SAFETY Operator Safety Never modify this vehicle through improper installation or use of accessories. Never exceed the stated load capacity fo r your vehicle. Cargo must be pr operly distributed and securely attached. Reduce speed and foll ow the instructions in this manual for carrying cargo or towing. Allow a greate r distance for braking. Nev[...]

14 SAFETY Safety Labels and Locations W arning labe ls have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully . If a label becomes illegible or comes of f, contact your Polaris dealer to purchase a replacement. Replacement safety labe ls are provided by Polaris at no charge. The part number is [...]

15 SAFETY Safety Labels and Locations Discretionary W arning W ARNING • Never operate this A TV on HILLS steeper than 25 d egrees 25 ° . T o prevent overturn on hilly ter- rain, use throttle and brakes grad- ually , and shift weight uphill. • REVERSE operatio n can be dan- gerous even at low speeds. S teer- ing becomes difficult. T o prevent l[...]

16 SAFETY Safety Labels and Locations “No Passenger” W arning W ARNING NEVER ride as a passenger . Passengers can cause a lo ss of control, resulti ng in SEVERE INJURY or DEA TH. 7175378 Age 16 W arning W ARNING Operating this A TV if yo u are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you ar[...]

17 SAFETY Safety Labels and Locations Clutch Cover W arning W ARNING NO STEP • Moving parts hazard under belt-clutch gu ard. T o prevent serious injury , do not operate vehicle wi th guard removed. • Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, whi ch can result in serious injury[...]

18 SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury . Helmet Always wear a helmet that meets or exceeds established safety stan- dards. Approved helmets in the USA and Ca nada bear a U.S. Dep artment of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE m[...]

19 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 o r use a shatterproof helmet face shield. Po laris recommends wearing approved Personal Prot ective Equi pment (PPE ) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make[...]

20 FEA TURES AND CONTROLS Switches Mode/Reverse Override Switch This vehicle is equipped with a re verse speed limi ter system.T o gain additional power while backing, depress the override switch. The override switch also allow s activation of All Wheel Drive in reverse, if the A WD switch is on. Th is switch is also used to toggle through the mode[...]

21 FEA TURES AND CONTROLS Switches Engine Stop Switch Move the stop switch ei ther left or right to the OFF position to stop the engi ne quickly . The engine will no t start or run when the switch is of f. Both the main switch and the engine stop switch will shut of f all electri- cal power to the vehicle, including lights. Main Key Switch Use the [...]

22 FEA TURES AND CONTROLS Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. Failure to check or maintain proper operation of the throttle system can result i n an accident if the thrott le lever sticks during [...]

23 FEA TURES AND CONTROLS Brake Lever Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activ ated disc type brakes that are activ ated by on ly one lever . Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any spongi[...]

24 FEA TURES AND CONTROLS Parking Brake Operating this vehicle while the parkin g brake i s engaged could result i n an accident and serious injury or death . Always check to be sure the parking brake is disengaged before operating. Locking the P arking Brake 1. Place the transmission in gear . 2. Squeeze and release the brake lever two or three ti[...]

25 FEA TURES AND CONTROLS Auxiliary Foot Brake The auxili ary brake syst em is intend ed to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Aggressively applying the auxiliary brake when backin g down a hill may cause rear tipover , which could result in serious injury or death. Use caution [...]

26 FEA TURES AND CONTROLS Choke The choke assists in st arting a cold engine. Refer to the engine starting procedure on page 36 for correct ch oke and throttle settings during start- ing. Fuel T ank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octa[...]

27 FEA TURES AND CONTROLS Automatic T ransmission Gear Selector The transmission gear selector is located on the right side of the vehic le. H: High Gear N: Neutral R: Reverse Whenever this vehicle is left unattended, always place the transmission in gear and lock the parking brake. Shifting gears with the engine speed above idle or while the vehic[...]

28 FEA TURES AND CONTROLS Recoil St arter If the battery is too weak to start the engine , use the recoi l starter . Follow the starting procedures on page 36, 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 you can feel the engine strokes. Tip : The rop[...]

29 FEA TURES AND CONTROLS All Wheel Drive (A WD) System (4X4 Models) The All Whee l Drive syst em is controlled by the A WD switch. When the switch is on 2X4, the vehicle is in two-wheel drive a t all times. When the switch is on A WD, the vehicle is in all wheel drive and the A WD indicator light in the instrument cluster will be on. When in A WD,[...]

30 FEA TURES AND CONTROLS Instrument Cluster Y our vehicle 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 this vehicle's speed to approximately 7-9 mph. Ref[...]

31 FEA TURES 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. Engine Hour Display Indicator 3. Speedometer 4[...]

32 OPERA TION Fuel Safety Gasoline is h ighly flammable and explosive under certain conditions. • Use extreme caution whenever handli ng gasoline. • Refuel with the en gine stopped. Refuel outdoors or in a well-ventilated area. • Never fill a fuel container while it's on the vehicle. S tatic electricity between the rack and container co [...]

33 OPERA TION Break-In Period The break-in period for your new Polaris vehicle is the first ten hours of operation, or the time it takes to use the first two full ta nks of gasoline. No single action on your part is as important as following the proce- dures for a proper break-in. Careful treatment of a new engine and drive components will result i[...]

34 OPERA TION Break-In Period Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 26. 2. Check the oil level on the dipstick. See page 61. Add oil if neces- sary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an op en area that allows room to famil- iarize yourself with vehi cle opera[...]

35 OPERA TION Pre-Ride Checklist If a proper inspection is not done before ea ch use, severe injury or dea th could result. Always inspect the vehicle before each use to ensure it's i n proper operating condition. Item Remarks P age Brake system/lever travel Ensure proper operation 23 72 Brake fluid Ensure proper level 70 Auxiliary brake Ensur[...]

36 OPERA TION S t arting the Engine 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. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. Tip : The starter interlock will prevent [...]

37 OPERA TION S t arting the Engine 8. T u rn 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 en gine starts. 9. If the engine does not start, return the key to the OFF position and wait five seconds before attemptin g to start again. Activate the starter f[...]

38 OPERA TION Driving Procedures 1. W ear protective riding ge ar . See page 18. 2. Perform the pre-ride inspection. See page 35. 3. Sit upright with both feet on th e footrests and both hands on the handlebars. 4. Star t the engine and allow it to warm up. 5. Shift the transmission into gear . 6. Check your surroun dings and determine your path of[...]

39 OPERA TION T urning the V ehicle Y our vehicl e 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 . 1. Slow down. 2. Steer in the direction of[...]

40 OPERA TION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freez- ing weather , follow these precautions: 1. Do not operate on exces- sively rough, slippery or loose terrain. 2. Slow down when enter- ing slippery areas. 3. Engage A WD (if equipped) before wheels begin to lose tracti[...]

41 OPERA TION Driving Uphill Braking and handling are greatly af fe cted when operating in hilly ter- rain. Improper procedure could cause loss of control or overturn and result in serious injury or death. Whenever traveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrai[...]

42 OPERA TION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not reco mmended. Improper procedure could cause loss of control or overturn. A v oid crossing the side of any hill unless absolutely ne cessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. A void crossing the side of a steep hill. 3. [...]

43 OPERA TION Driving Downhill When driving downhill, follow these precautions: 1. Before operating your vehicle, le arn how to use the auxiliary brake for emergency situations (if single -lever brakes become inoperable). 2. Always check the terrain carefully before descending a hill. 3. Shift your weight uphill. 4. Drive straight downhill. 5. Slow[...]

44 OPERA TION T urning Around on a Hill (K-T urn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.4 m)[...]

45 OPERA TION T urning Around on a Hill (K-T urn) 1. S top and lock the parking brake while keeping body weight uphill. 2. Leave the transmission in forward and shut off the engine. 3. Dismount on the uphill side of the ve hicle, or on the left if the vehi- cle is pointin g straight uphill. 4. Staying uphill of the vehicle, turn the handlebars full[...]

46 OPERA TION Driving Through W ater Y our vehicle 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 crossing. 2. Choose a crossing where both banks have gradual inclines. 3. A vo id operating through dee[...]

47 OPERA TION Driving Through W ater If it’ s unavoidable to enter water de eper than the footr est level: • Proceed slowly . A void rocks and obstacles. • Balance your weight carefully . A void sudden movements. • Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes. If your vehicle become[...]

48 OPERA TION Driving Over Obst acles 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. T ravel slowly and use extra cau tion when operating on unfamiliar[...]

49 OPERA TION 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 bra kes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly . 7. Do not use the override switch un l[...]

50 OPERA TION Hauling Cargo Overloading the vehicl e or carrying or to wing ca rgo improperly can alter vehicle handling and may cause loss of control or brake instability . Always follow the se precautions when hauling cargo . • Read and understand the load distribut io n warnings listed on the vehicle warning labels. • Never exceed the stated[...]

51 OPERA TION Hauling Cargo Y our vehic le has been designed to ca rry or tow a certain amount of load. Always read and understand the load distribut ion warning labels on the vehicle, and never exceed the weight capacities outlined in the specifi- cations section of the owner's manual and on the safety labels. Carg o weight should be even ly [...]

52 OPERA TION Parking on an Incline A void parking on an incline if possible. If it's unavoidable, follow these precautions: 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. Always block the rear wheels on th e downhill side. 5. T urn the fuel valve off.[...]

53 EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with gover nmental noise level requi rements. S p ark Arrestor Y our Polaris vehic le has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor r[...]

54 MAINTENANCE Periodic Maintenance Chart Maintenance intervals in th e following ch art are based upon averag e riding conditions. V ehicles subjected to severe use mu st be inspected and serviced more frequently . Inspect, clean, lubricate, adjust and replace parts as necessary . When inspection reveals the need for repl acement parts, use genuin[...]

55 MAINTENANCE Periodic Maintenance Chart Improperly performing the p rocedures marked with a  could result in component failure and cause an accident, wh ich may result in serious inj ury or death. Always have an authorized Pola ris de aler perform these services. Maintenance Chart Key X Perform these operations more of ten for vehicles subject[...]

56 MAINTENANCE Periodic Maintenance Chart Perform all services at whichever main tenance interval is reached first. X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calend[...]

57 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) X General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots, cables, etc. Carburetor float bowl 50 H 6 M 500 (800) Drain bowl periodically and prior to storage Q E Throttle Cable/ ETC Switch 50 H 6 M 500 (800) In[...]

58 MAINTENANCE Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use. E Emission-Related Service Q Have an authorized Polaris dealer perform these services. Item Maintenance Interval (whichever comes first) Remarks Hours Calendar Miles (Km) Q Clutches (drive and driven) 100 H 12 M 1000 (1600) Inspect[...]

59 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Peri- odic Maintenance Chart beginning on page 54. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Lube Method Engine Oil PS-4 PLUS P erformance Synthetic 2W-50 See page 60. Brake Fluid DOT 4 Only See pag[...]

60 MAINTENANCE Engine Oil Oil Recommendations Always change the oil filter whenever changing oil. 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 Polari s oil is not used. Always use 2W -50 oil. Follow the manufacturer's r[...]

61 MAINTENANCE Engine Oil Oil Level The oil dipstick is located behind the recoil on the right side of the vehicle. 1. Position the vehicle on a level surface. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Star t the engine. Allow it to idle for 30 seconds. Stop the engi ne. 5. Remove the dip stick. W ipe it dry with a clean c[...]

62 MAINTENANCE Oil and Filter Change Hot oil may result in serious burns. Do not allow hot oil to contact skin. Always change the oil and filter at th e intervals outlined in the Periodic Maintenance Chart beginning on page 54. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Place the transmission [...]

63 MAINTENANCE Oil and Filter Change 1 1. 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 new oil filter . After the filter contacts the [...]

64 MAINTENANCE T ransmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on p age 54. Maintain the oil level at the bottom of the fill plug hole. See page 105 for the part numbers of Polaris products. The fill plug is located on the left side of the vehicle, under the rear f[...]

65 MAINTENANCE T ransmission 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. T o rque to specification. See page 64 for recom- mendations.[...]

66 MAINTENANCE T ransmission 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 drain completely . 8. Clean and reinstall the d[...]

67 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) Always check and change the demand drive fluid at th e inter- vals outlined in the Periodic Maintenance Chart beginning on page 54. W e recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of compo- nents. See page 105 for th[...]

68 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) 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 recommend ed oil as needed to bring the level to the bottom of the fill hole th[...]

69 MAINTENANCE Front Gearcase (Dem and Drive) Fluid (if equipped) 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 1 1 mm wrench. 7. Allow the oil to drai[...]

70 MAINTENANCE Brake Fluid Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill. The brakes should feel firm when they're applied. Spongy or weak brakes may indi cate a fluid leak or low fluid level. A lo w fluid level may also mean that brake pads are wo rn and[...]

71 MAINTENANCE 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. V iew the fluid level through the indicator win- dow (eye) on [...]

72 MAINTENANCE Brakes The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the hand lebar . The auxiliary foot brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections The following checks are recommende d to keep the brake system in good operating condition. Check more ofte[...]

73 MAINTENANCE T oe Alignment Do not attempt to adjust tie rod ali gnment. All tie rod adjustments should be performed by an authorized Polaris dealer . Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignm ent is 3-6 mm toe out. 1. Position the vehicle on a level surface. 2. Place the handlebars in a str[...]

74 MAINTENANCE Camber and Caster The camber and caster are non-adjustable. S pring Adjustment s The front and rear shock absorber springs are adjustable. Rotate the adjuster either clockwise or counterclockwise to increase or decrea se spring tension. Always ad just both sides equally . Tip : Accessory springs are available through your Polaris dea[...]

75 MAINTENANCE Handlebars The handlebars can be adjusted for rider preference. Improper adjustment of the hand lebars or incorrect torquing of the adjuster block tighteni ng bolts can cause limited steering or loosen in g of the handlebars, resulting in loss of control and possible serious personal inju ry or death. Follow the adjustment procedures[...]

76 MAINTENANCE Carburetor This vehicle is calibrated at the fa ctory for optimal performance at alti- tudes ranging from zero to 6,000 feet (1800 m) and temperatures of +40 degrees F . (4 degrees C.) or higher . Abov e 6000 feet (1800 m) the engine air/fuel mixture becomes overly rich and the engine loses approximately 3% of its power for ea ch 100[...]

77 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 sli de it far enough to ex pose the end of the inline cable adjuster . 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16"[...]

78 MAINTENANCE S teering Assembly The steering assembly of this vehicle should be checked period ically for loose nuts and bolts. If loose nu ts and bolts are found, see yo ur Polaris dealer for service before operati ng the vehi cle. Side Panel Remova l 1. Remove the seat. 2. Grasp the top of the side panel and pull it outward to remove it. Footwe[...]

79 MAINTENANCE Ti re s Operating your vehicle with worn tires, improperly in flated tires, non-standard tires or improperly inst alled tires will af fect vehicle handling an d could cause an accident resulting in serious injury or death. • Maintain proper tire pressure as described on the label on you r vehicle and in the owner's manua l. ?[...]

80 MAINTENANCE Ti re s 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 . 5. Place a suitable stand under the footrest frame to raise the whee l slightly off the ground. 6. Remove the wheel nut s. 7. Remove the wheel.[...]

81 MAINTENANCE Ti re s Wheel Inst allation Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result i n serious injury or death. Always ensure that all nuts are torqued to specification. Do not se rvice axle nuts that have a cotter pin installed. See your Polaris dealer . 1. Place the wheel on the wheel hub [...]

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. W ash the sl eeve in soapy water, then rinse [...]

83 MAINTENANCE Light s 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 su rface with the headlight approxi- mately 25 ft. (7.6 m) from a wall. 2. Place the transmission in neutral. 3. Lock the parking brake. 4. Measure th[...]

84 MAINTENANCE Light s Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and t aillights frequently . Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled. Headlamp Replacement When servicing a halo gen lamp, don't touch[...]

85 MAINTENANCE Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi- tions. Drain the housing before storing the vehicl e. 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. S top the engine. 4. Remove the drain screw on t[...]

86 MAINTENANCE Spar k P l ug s Sp ark Plug Recommendations Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginni ng on page 1 10 for the recom- mended spark plug t ype and gap for your vehicle. T orque spark plugs to specification. Sp ark Plug I[...]

87 MAINTENANCE Spar k P l ug s Sp ark Plug Inspection 4. Inspect the electrodes for wear and carbon buildup. Replace worn or fouled plugs. V erify that the gap is at specification before installation. 5. Reverse the procedure for spark plug installation. T orque to specification. Sp ark Plug Condition Normal Spark Pl ug The normal insulator tip is [...]

88 MAINTENANCE V ehicle Immersion If your vehicle becomes immersed, ma jor engine damage can resul t if the machine is not thoroughly in spected. T a ke th e vehicle to your dealer before star ting the engi ne. If it's impossible to take your vehicle to a dealer before sta rting it, follow the steps outlined below . 1. Move the vehicle out o f[...]

89 MAINTENANCE S p ark Arrestor Failure to heed the following warnings whil e servicing the sp ark arrestor could result in serious injury or death. The exhaust system c an get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustible material[...]

90 MAINTENANCE P VT System Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a hig h speed. The PVT system has been precision balanced. Any modi fication will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speed[...]

91 MAINTENANCE P VT System PVT Drying There ma y be some ins tances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Move the vehicle out o f the water . 2. Remove the PVT drain plu g. Use a 17 mm wrench, a flat screwdriver , or the spark plug wrench . 3. Allow the water to dra[...]

92 MAINTENANCE Battery Improperly connecting or disconnecting battery ca bles 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. Battery electrolyte is poisonous. It contains sulf[...]

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 batte ry vent tube. 6. Disconnect the black (nega- tive) battery cable first. 7. Disconnect the red (posi- tive) battery cable las t. 8. [...]

94 MAINTENANCE Battery Battery Inst allation Using a new battery that has not been fully ch arged 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 is fully char ged. 2. Place the batter y in th[...]

95 MAINTENANCE Battery Battery S torage Whenever the vehicle is not used for a period of three month s or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage an d rechar ge as needed to maintain a full charge. Battery charg[...]

96 MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehi cle to p revent damage from leak- ing or spilled electrolyt e during char ging. See pa ge 93. 2. Charge the battery with a char ging output no larger than 1/10 of the battery’ s amp/hr rating. Charge as needed to raise the specific grav- ity to 1.27[...]

97 MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition befo re and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant cur rent charger @ standard amps specifie d on top of battery) 100% 12.8-13.0 volts None, check at 3 mos. from date of manufacture None required 75%-100[...]

98 MAINTENANCE Cleaning and St orage W ashing th e V ehicle Keeping your Polaris vehicle clean will not only improve its appearance but it can also extend the life of various co mponents. High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including inse[...]

99 MAINTENANCE Cleaning and St orage W ash ing the V ehicle If a high pressure water system is u sed for cleaning (n ot recommended), exercise extreme caution. The wate r may damage components and could remove paint and lab els. A void direc ting the water stream at the follow- ing items: • Wheel bearings • T ransmission seals •B r a k e s ?[...]

100 MAINTENANCE Cleaning and St orage 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 susceptible to corrosion if not properly cleaned. Cle[...]

101 MAINTENANCE Cleaning and St orage Sto ra ge Tips S tarting the engin e during the storage period will di sturb 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 recommended. See page 98. Stabilize the F uel 1. F[...]

102 MAINTENANCE Cleaning and St orage Sto ra ge Tips Fluid Levels Inspect the fluid levels. Change flu ids as recommended in the Periodic Maintenance Chart beginn ing on page 54. • Demand drive unit (front gearcase) (if equipped) • T ra nsmission • Brake fluid (change every two years and any time the flui d looks dark or contaminated) Fog the[...]

103 MAINTENANCE Cleaning and St orage Sto ra ge Tips Inspect and Lubricate Inspect all cables and lubricate al l areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 54. Battery Storage See pages 95-96 for storage and charging procedures. Storage Area/Covers 1. Set the tire pressure and safely su pport the vehicle[...]

104 MAINTENANCE T ransporting the V ehicle Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in gear . 3. Lock the parking brake. 4. T urn the fuel valve off. 5. Secure the fuel cap, oil cap and seat. 6. Remove the key to preven t loss during transporting. 7. Always tie the frame of the vehicle to[...]

105 POLARIS PRODUCTS Pa rt Number Descr iption Engine Lubri cant 2870791 Fogging Oil (12 oz. Aerosol) 2876244 PS-4 PLUS Performance Synthetic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS Performance Synt hetic 2W -50 4-Cycle Oil (gal.) Gearcase / T ransmission Lubricants 2873602 Premium AGL Synthetic Gearcase Lubricant (qt.) 2873603 Premium AGL Synth[...]

106 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 incl ine Use low range (if equipped) or turn around using the K- turn (see page 44). Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range (if[...]

107 TROUBLESHOOTING Engine Doesn't T urn Over Engine T urns Over , Fails to St art Engine Backfires Possible Cause Solution Blown fuse Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Chec k all connections and tighten Loose solenoid connections Chec k all connections and tighten Possible Cause Soluti[...]

108 TROUBLESHOOTING Engine Pings or Knocks Engine Runs Irregularl y , St alls or Misfires Possible Cause Solution Poor quality or low octane fu el 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 low Adjust idle speed Possible Cause Solution[...]

109 TROUBLESHOOTING Engine Stop s 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 W ater is present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/or replace spark plugs Fouled [...]

110 SPECIFICA TIONS * Based on EU Directive 76/432/EC HA WKEYE 2X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W eight 525 lbs. (238 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 15.2 oz. (450 ml) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45 kg) Hitch T ongue W eight Capacity 75 lbs. [...]

111 SPECIFICA TIONS Jetting Chart Clutching Chart HA WKEYE 2X4 T ires/Pressure, Front 22x7-12 / 5 psi (34.5 KPa) T ires/Pressure, Rear 2 2x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with 7" (18 cm) travel Rear Suspension Progressive ra te with 8" (20 cm) travel Shock Adjustment CAM Brakes, Front Single-Control Hydraulic Di[...]

112 SPECIFICA TIONS * Based on EU Directive 76/432/EC HA WKEYE 4X4 Gross V ehicle W eight 930 lbs. (422 kg) Dry W eight 550 lbs. (250 kg) Fuel Capacity 4.5 gal. (17 l) Engine Oil Capacity 2 qts. (1.9 l) T ransmission Oil 20.3 oz. (600 ml) Demand Drive Flui d 5 oz. (148 ml) Front Rack Capacity 70 lbs. (32 kg) Rear Rack Capacity 100 lbs. (45 kg) Hitc[...]

113 SPECIFICA TIONS Jetting Chart Clutching Chart HA WKEYE 4X4 Drive Ratio, Front 3.6:1 Drive Ratio, Final 15.18:1 T ires/Pressure, Standard models Front 22x7-12 / 5 psi (34.5 KPa) Rear 22x10-12 / 5 psi (34.5 KPa) T ires/Pressure, LE models Fr ont 23x7-12 / 5 psi (34.5 KPa) Rear 23x10-12 / 5 psi (34.5 KPa) Front Suspension MacPherson strut with 7&q[...]

114 DECLARA TION OF CONFORMITY Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements ap plicable to off-road all-terrain vehicles. PRODUCT IDENTIFICA TION APPLICABLE EUROPEAN DIRECTIVES TEST /[...]

115 W ARRANTY LIMITED W ARRANTY Polaris Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR LIMITED W ARRANTY on all components of th e Polaris vehicle against defects in material or workmanshi p. This warranty covers the parts and labor charges for repair or replacement of defective parts which are cove red by this warranty . This[...]

116 W ARRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIES Warranty does not apply to pa rts exposed to friction surfaces, stresses, environmental conditions and/or contaminati on, for which they were not designed or not intended, including but not limited to the following items: W arranty applies to the product only and does not allow for coverage o[...]

117 W ARRANTY LIMIT A T IONS OF W ARRANTIES AND REMEDIES This warranty does not cover the use of unauthor ized lubricants, chemical s, or fuels that are not compatibl e with the vehicle. The ex clusive remedy for breach of this warranty shall be, at Polaris' exclusive option, repair or replacement of an y defective materials, or components or [...]

118 MAINTENANCE LOG Present this section of your manual to your dealer each ti me your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and ser- vices perfor med. DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

119 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMEN TS[...]

120 MAINTENANCE LOG DA TE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

121 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 103 Age Restricti ons . . . . . . . . . . . . . . . . . 6 Air Filte r . . . . . . . . . . . . . . . . . . . . . . 82 All Wheel Drive Switch . . . . . . . . . . 21 All Wheel Drive System . . . . . . . . . . 29 AWD Switc h . . . . . . . . . . . . . . . . . . . 29 AWD System . . . . . . . .[...]

122 INDEX H Handlebar Adjus tment . . . . . . . . . . . 75 Hauling Cargo . . . . . . . . . . . . . . . 50-51 Headlamp Replacem ent . . . . . . . . . . 84 Headlight Be am Adjustment . . . . . . 83 Headlight Sw itch . . . . . . . . . . . . . . . 21 Helmet . . . . . . . . . . . . . . . . . . . . . . . 18 I Idle RPM Adjust ment . . . . . . . . . . . 76[...]

123 INDEX S Switches AWD Switch . . . . . . . . . . . . 21, 29 Engine Stop Switc h . . . . . . . . . . 21 Headlight Switch . . . . . . . . . . . . 21 Main Key Switc h . . . . . . . . . . . 21 Mode/Reverse Ove rride Switch 20 T Taillight . . . . . . . . . . . . . . . . . . . . . . . 84 Throttle Cable Freeplay . . . . . . . . . . 77 Throttle Leve r .[...]