Polaris 9920183 manuale d’uso

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W ARNING The engine exhaust from this product contains chemic als known to cause cancer , birth defects or other reproductive harm. A car d cont aining import ant A T V saf et y inf ormat ion should be at t ached t o the owner ’s manual on the next page. If y ou cannot locate this car d, or if it has been removed, please call 1- 800-342-3764 f or[...]

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2 Copyr ight 2005 Pola r is Sa le s I nc. All inf orm a t ion c onta ine d wi thin t his publi ca ti on is ba se d on the la te st produc t in form atio n at th e time of pu b lication . Du e to con stant imp ro vem en ts in th e d esign an d q uality o f pr oduct ion c omponent s, som e minor dis cr epa nc ie s ma y re sul t be twe e n the a ct ua[...]

3 WELC OM E Tha nk you for pur chasing a Polar i s veh icle , and we lcome to our w orld-wide family of Polaris ow ners. W e pr oudly produc e an e xciting line of utility a nd recr eationa l pr oducts. S Snowmobiles S All- ter rain ve hicles (A TVs) S RANGER utility vehicle s S V ict or y mo to rcycl es[...]

4 WELC OM E W e belie ve Polaris sets a standa rd of exc ellenc e for all utility and rec rea tional vehicle s manuf ac t ure d in the world toda y . Many years of expe rience ha ve gone into the engineer ing, design, and deve l opment of your Polaris vehic le, m aking it the finest machine w e’ve eve r produce d. For safe a nd e njoyable ope rat[...]

5 TABL E OF CONTENT S WELCO ME 3 ....................................................... VEHICLE I DENTI FI CA T ION NUM BERS 6 .............................. SAF ETY 8 ......................................................... FEA T URES AND CONTROL S 48 ..................................... OPE RA T ION 65 .........................................[...]

6 VEHICLE IDENT IFI CATION NUMBERS Record your A TV’ s identifi cation num be rs and key number in the sp aces pr ovided. Remove t he spare key and store i t i n a safe place. Y our key can be duplicat ed only by mating a Polaris ke y blank with one of your e xisting keys. If both ke ys are lost, the ignition switc h must be r epl aced. 2 1 31XX [...]

7 VEHICLE IDENT IFI CATION NUMBERS V ehic le Model Number: Frame V IN ( 1)(lef t s ide): Engi ne Seria l Numbe r (2)(ri ght sid e): Key N umber (3):[...]

8 SA FE TY Safety D ecals an d Locatio ns W arnin g decals h ave been placed on th e A TV fo r your protection. R ead and foll ow the in st ruct io ns of t he decal s on t he A T V carefull y . If any o f the decal s dep ict ed in t hi s man ual differ from t he decals on your A TV , al ways read and follow the ins tru cti ons of t he decal s on th[...]

9 SA FE TY Safety D ecals an d Locatio ns Locat ion B D Never operate this vehicle on HILLS steeper than 25 degrees 25 ° . T o prevent flipover on hilly terrain, when going up or down, use thr ottle and brakes gradually . D REVERSE oper ation can be dangerous, even at low speeds. Steering becom es diff icult. T o prevent flipover , avoid sudden br[...]

10 SA FE TY Safety D ecals an d Locatio ns E D F Locat ion F H G I 7172566 W ARNING Locat ion E[...]

11 SA FE TY Safety D ecals an d Locatio ns A TTENTI ON S Oper ati on of this v ehic le without the air filter element wil l sev erely damage the engine. S Clean pre-filter element often, more frequent c leaning required in dus ty conditi ons. Do not operate vehic le without pre-filter . S Oper ati on of this vehi cle without engine breather filter([...]

12 SA FE TY Sa fe Riding Gea r Always we ar c lothing suited to the type of r iding. A TV riding re quires spec ial protec tive clothing for comf ort and to reduc e t he cha nce of injury . 1. Helmet Y our helme t is the most important piece of pr otective ge ar for s afe rid in g. A hel met can p reven t a s evere head in ju ry . Sel ect an approv[...]

13 SA FE TY Sa fe Riding Gea r 2. Eye Prot ection Do not de pend on sungla sses for proper e ye prote ction. A pair of goggles or a helmet fa ce shield of fe r the best prote ction for your eye s. They should be kept c lea n and be of shatte rproof de sign (be aring the mar kings z2.1 or VESC 8). 3. Gloves Of f-road st yle gl oves with knuckle pads[...]

14 SA FE TY Operator S afety W ARNING Failur e to f ollow t he warnings c ontained in t his m anual can res ult in s erious injur y or death. A Polar is A T V is not a t oy and c an be hazardous to oper ate. T his vehic le handles different ly than ot her vehicl es, such as m otorcycles and ca rs. A collision or rollover can occ ur quick ly , even [...]

15 SA FE TY Operator S afety Know Y our V ehic le As the opera tor of the A TV , you are r esponsible for your saf ety , the saf ety of others, and the prote ction of our envir onment. R ea d and understa nd your owner ’ s manua l, which includes valua ble informa tion about all aspec ts of your A TV , including safe oper ating proce dures. Sa fe[...]

16 SA FE TY Operator S afety The f ollowing two page s identify signa l words a nd symbols that appe ar in this manua l. Y our sa fe ty is involved w hen these w ords and symbols a re used. Bec ome fa miliar with their mea nings before r eading the manua l. The safet y alert s ymbol , on your vehicl e or in t his manual, alert s y ou to t he potent[...]

17 SA FE TY Operator S afety CAUTION The safet y alert caut ion indicat es a pot ent ial hazard t hat may r esult in minor per sonal injury or damage t o the v ehicle. CAUTION A caut ion indicat es a sit uat ion that may result in damage t o t he vehicle. NOT E: A note will aler t y ou to im port ant inf orm ation or inst ruct ions.[...]

18 SA FE TY Operator S afety W ARNING Serious injury or deat h can res ult if you do not f ollow thes e inst ruct ions and procedur es, which are out lined in f urt her det ail within y our owner ’s manual. S Read this ma nual and all labe ls care fully , and follow the oper ating pr ocedure s descr ibed. S Neve r operate a n A TV without proper [...]

19 SA FE TY Operator S afety S Neve r operate a n A TV on a public str ee t , road or highway , i ncluding a dirt or gra vel road. S Neve r operate an A TV without wea ring an appr oved he lmet that fits proper ly . Always wea r eye prote ction (goggles or fac e shield), gloves, boots, a long-sleeve d shirt or j ac ket, and long pa nts. S Neve r co[...]

20 SA FE TY Operator S afety S Neve r operate on exc essively rough, slippery , or loose t er rain. S Always follow proper turning proc edures a s described in this manua l. Prac tice turning at lo w speed s befor e attem pt in g to t urn at fas t er speeds . Do not t urn at ex cessi ve sp eeds . S Always ha ve the A TV inspec ted by a n author ize[...]

21 SA FE TY Operator S afety S Alwa ys f ollow prope r proce dures for cr ossing the side of a hill. A void hills with e xce s- sivel y slippery or loos e su rfaces. S hift your weight to t he uphi ll side of the A TV . Never atte mpt to turn the A TV ar ound on any hill until you’ve maste red ( on leve l ground) the turning te chnique outlined i[...]

22 SA FE TY Operator S afety S A void opera ting t he A TV through dee p or fast- flowing water . If it’ s unavoidable , trave l slowly , balance your weight ca refully , a void sudde n moveme nts, and maintain a slow and ste ady f orwar d motion. Do not make sudde n t urns or stops, and do not make sudden throttle c hanges. S W et bra kes may ha[...]

23 SA FE TY Operator S afety Equipme nt Modific ati ons W e are c oncer ned for the saf ety of our customers and for the gene ral public. Theref ore, we strongly r ec ommend that consume rs do not install on a Polar i s A TV any e quipment that may incr ea se t he spee d or power of the vehic le, or make any other modific ations to the vehic l e fo[...]

24 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t his A TV wit hout proper ins tr uct ion. WHA T CAN HAPPEN : T he ris k of an accident is gr eatly increas ed if t he operat or does not know how t o operat e the A TV pr operly in different sit uat ions and on differ ent ty pes of t errain. HOW TO A VO ID THE HAZARD : B eginning[...]

25 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Failur e to f ollow t he skill and ex perience r ecomm endations for th is A TV . WHA T CAN HAPPEN : S evere injur y and/ or deat h could occ ur if a beginner or inexperienc ed driver operat es t his A T V . HOW TO A VO ID THE HAZARD : O nly oper ator s wit h advanced s kills and s ubst anti[...]

26 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Failur e to f ollow t he age recom mendat ions f or t his A T V . WHA T CAN HAPPEN : S evere injur y and/ or deat h could occ ur if a child under t he minimum age rec ommendat ion operat es t his A T V . Even t hough a child m ay be wit hin the r ecomm ended age group f or operat ing som e A[...]

27 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Carry ing a passenger on an A T V . WHA T CAN HAPPEN : Car rying a pas senger great ly reduces t he operat or ’s ability to balance and cont rol t he A T V , which c ould cause an ac cident and injury t o t he operat or and/ or pass enger . HOW TO A VO ID THE HAZARD : Nev er carr y a passe[...]

28 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating an A TV on paved sur fac es, including sidewalk s, paths , parking lot s, and driv eways. WHA T CAN HAPPEN : A TV t ires are designed for off-r oad use. O perat ing on paved sur fac es may adv ersely affect t he handling of t he A T V and could res ult in los s of cont rol, accide[...]

29 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Operat ing this A TV on public st reet s, r oads or highways. WHA T CAN HAPPEN :T h e A T V could collide wit h anot her vehic le. HOW TO A VO ID THE HAZARD : Never oper ate t he A T V on any public st reet , r oad or highway , including dir t and gravel r oads. In m any st at es it ’ s il[...]

30 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t his A TV without wearing an appr oved helmet , eye prot ect ion and prot ect ive clot hing. WHA T CAN HAPPEN : O perat ing an A T V without an approv ed helmet increas es t he risk of a sever e head injury or death i n the ev ent of an accident . Oper ating wit hout eye prot ect[...]

31 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t he A T V af t er cons uming alcohol or drugs. WHA T CAN HAPPEN : Cons umpt ion of alc ohol and/or drugs c ould serious ly affec t operat or judgment . React ion tim e may be s lower and operat or balanc e and percept ion could be affec ted. Consuming alc ohol and/or drugs bef or[...]

32 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : A ttemp ting w he eli es, jumps and ot her s tunt s. WHA T CAN HAPPEN : Atte mpti ng stu nts increas es t he chance of an acc ident, including an overt urn. HOW TO A VO ID THE HAZARD : Nev er att empt wheelies, jumps , or other st unts . Avoid ex hibition driving.[...]

33 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Failur e to ins pect the A TV bef ore oper ating. Failur e to pr operly m aintain t he A T V . WHA T CAN HAPPEN : P oor maint enance inc reases the pos sibilit y of an accident or equipment damage. HOW TO A VO ID THE HAZARD : A lways ins pect your A TV bef ore eac h use t o make sure it ’s[...]

34 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Removing hands f rom t he handlebars or feet f rom t he foot pegs dur ing operat ion. WHA T CAN HAPPEN : Rem oving even one hand or foot can r educe abilit y t o cont rol the v ehicle or c ould cause los s of balance and eject ion f rom t he A T V . If t he operat or ’s foot is not fir mly[...]

35 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Failur e to us e ext ra caut ion when operat ing t he A T V on unfam iliar ter rain. WHA T CAN HAPPEN : Unf amiliar t err ain may cont ain hidden rocks, bumps, or holes t hat c ould cause los s of cont rol or overt urn. HOW TO A VO ID THE HAZARD : T ravel slowly and us e ext ra caut ion when[...]

36 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Fail ure to use extra caut ion when operat ing on exces sively rough, slippery or loos e ter rain. WHA T CAN HAPPEN : O perat ing on exces sively r ough, slipper y or loose ter rain could caus e loss of t ract ion or los s of cont rol, which could r esult in an accident or overt urn. HOW TO [...]

37 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : T urning im properly . WHA T CAN HAPPEN : I mpr oper t urns c ould cause los s of cont rol and lead t o a collision or overt urn. HOW TO A VO ID THE HAZARD : A lways f ollow proper procedur es for t urning as descr ibed in the owner ’ s manual. Prac tic e tur ning at s low speeds bef ore a[...]

38 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Climbing hills improper ly . WHA T CAN HAPPEN : I mpr oper hill clim bing could caus e loss of cont rol or over tur n. HOW TO A VO ID THE HAZARD : A lways f ollow proper proc edures f or climbing hills as descr ibed in the owner ’ s manual. Always check the t err ain caref ully bef ore as [...]

39 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : T rav eling downhill improper ly . WHA T CAN HAPPEN : I mpr operly desc ending a hill could caus e loss of cont rol or over tur n. HOW TO A VO ID THE HAZARD : Always follow proper pr ocedures f or t raveling down hills as des cribed in t he owner ’s manual. NOT E: A special t echnique is r[...]

40 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Im properly c ross ing hills and t urning on hills. WHA T CAN HAPPEN : I mpr operly c ross ing or tur ning as hills c ould cause los s of cont rol or overt urn. HOW TO A VO ID THE HAZARD : Nev er att empt to t urn t he A T V ar ound on any hill unt il you’ve mast ered t he t urning t echni[...]

41 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : St alling, r olling or improper ly dism ounting while c limbing a hill. WHA T CAN HAPPEN : T he vehic le could over tur n. HOW TO A VO ID THE HAZARD : M aintain s teady speed when clim bing a hill. If all f orward s peed is lost : Keep your weight uphill. Apply f ront br akes gradually . Whe[...]

42 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Im properly operat ing over obs tac les. WHA T CAN HAPPEN : O perat ing over obst acles c ould cause los s of cont rol or overt urn. HOW TO A VO ID THE HAZARD : B efor e operat ing in a new area, check for obst acles. Avoid operat ing over large obs tac les suc h as roc ks and f allen tr ees[...]

43 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t he A T V t hrough deep or fas t- flowing wat er . WHA T CAN HAPPEN : Tires may float , c ausing loss of t rac tion and loss of c ontr ol, which could lead t o an acc ident or overt urn. HOW TO A VO ID THE HAZARD : Avoid operat ing t he A T V thr ough deep or fas t- flowing wat e[...]

44 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t his A TV wit h impr oper t ires, or wit h impr oper or uneven t ire pres sure. WHA T CAN HAPPEN : Us e of im proper t ires , or operat ion of t he A T V wit h impr oper or uneven t ire pr essur e, c ould cause l oss of cont rol or accident . HOW TO A VO ID THE HAZARD : A lways u[...]

45 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t he A T V wit h impr oper modif icat ions. WHA T CAN HAPPEN : I mpr oper inst allat ion of ac cess ories or modif icat ion of t he A T V may c ause changes in handling, whic h could lead t o an accident . HOW TO A VO ID THE HAZARD : Nev er modif y t he A T V t hrough im proper in[...]

46 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating on f roz en bodies of water . WHA T CAN HAPPEN : S evere injur y or deat h can r esult if t he A T V and/ or t he operat or f all thr ough the ic e. HOW TO A VO ID THE HAZARD : Nev er operat e t he A T V on a f rozen body of wat er . W ARNING POTENTI AL HAZ ARD Im properly operat [...]

47 SA FE TY Operator S afety W ARNING Oper ating a dam aged A T V can r esult in an accident wit h serious injury or death. Af t er any over tur n or acc ident, have a qualif ied ser vice dealer inspec t t he entir e machine for possible dam age, inc luding (but not lim ited t o) br akes, t hrot tle and s teer ing systems. W ARNING Saf e operat ion[...]

48 FEAT URES AND CONTROL S Engine Electr ical Switches 1 2 3[...]

49 FEAT URES AND CONTROL S Engine Electr ical Switches 1 . Sta rt But ton - The start button engage s the star ter . Always re lease the star t button as soon as the engine starts. 2 . Engine St op Swit ch - The purpose of this switch is to provide the ope ra tor with a quick mea ns of engine shutdown in case of a n e mer gency . The engine will no[...]

50 FEAT URES AND CONTROL S Lights 1. Headlight HI/ LO Swit ch 2. High T emp I ndicat or Lam p 3. Neutr al Indic ator Lamp 4. Revers e Indic ator Lamp 1 2 3 4[...]

51 FEAT URES AND CONTROL S Light S witche s The light switch is loca ted on the lef t handle bar . It’ s used to turn the lights on a nd of f and to switc h t he lights f rom HI to LO . NOT E: T he lights won’t work unles s the key is in t he ON position and t he engine st op swit ch is in t he RUN posit ion. W ARNING Oper ating t he A T V on s[...]

52 FEAT URES AND CONTROL S W ARNING Oper ating an A TV wit h st ick ing or impr operly oper ating t hrot t le cont rols c ould cause an accident and lead t o sever e injury or death. Never s tar t or operat e an A T V wit h a st icking or improper ly operat ing t hrot tle. Alway s cont act y our dealer for s ervic e if thr ott le problems ar ise. F[...]

53 FEAT URES AND CONTROL S El ectr onic Thr ottle Contr ol This A TV is equipped w ith Polaris Ele ctronic T hrottle Control (E TC), wh ich is de signed to re duce the r isk of a f roze n or stuc k throttle. I f the throttle c able should stic k in an open position when the opera tor rele ase s the throttle le ver , the engine w ill stop, and powe [...]

54 FEAT URES AND CONTROL S Foot Br ake Y our Polar is A TV has a foot peda l (1) that ac tivates the r ear bra kes. It’ s located in f ront of the right- hand footpeg ( 2) and is opera ted by the r ight foot. If the re ar whe els slide while using the foot brake, r educ e bra ke peda l pre ssure to brake the whee l s without skidding. Check the b[...]

55 FEAT URES AND CONTROL S Br ake L ever The Preda tor A TV has a single brake le ver for the front bra kes. It’ s loca t ed on the right handleba r . The f ront brak es are app li ed b y s queezi ng th e brake l ever ( 1) towar d the handleba r . The front brake s a re hydraulic ally acti vat ed d is c ty pe b rakes . Alway s t est brake l ever [...]

56 FEAT URES AND CONTROL S Master Cylinder The m ast er cyli nd er (2) is l ocat ed on t he rig ht -hand h andl ebar . C heck t he brak e flui d lev el before each ride. The flui d level can be seen t hrough the indi cator window (3) on the to p of the maste r cylinder . This eye will appe ar da rk wh en the fluid le vel is full. Whe n fluid nee ds[...]

57 FEAT URES AND CONTROL S Park in g Bra k e W ARNING Oper ating t he A T V while t he park ing brake is engaged could res ult in an ac cident and serious injury or deat h. Alway s chec k t o be sure t he park ing brake is disengaged befor e operat ing. Sett ing t he Parking B rake 1. Plac e the tra nsmission in first gear or ne utral. 2. S qu eeze[...]

58 FEAT URES AND CONTROL S Park in g Bra k e Importa nt Sa fegua rds S The pa rking bra ke ma y relax if le ft on for a long period of time. Alwa ys block the whe els to pre vent rolling. S Alwa ys block the whe els on the downhill side of the A TV if leaving it parke d on a hill. Another option is to park the A TV in a side hill position. S Neve r[...]

59 FEAT URES AND CONTROL S Fuel V alve The fuel valve (1 ) is l oca t ed under the fue l ta nk on the l ef t side of the A TV . It has three positions: OFF: F or vehic le storage a nd when transpor ting. ON: For normal opera tion. RES: F or r eserve supply if main supply is exha usted. NOT E: T here’s about a 5 t o 8 mile ( 8 to 13 k m) r ange on[...]

60 FEAT URES AND CONTROL S Fuel T ank The f uel tank fille r ca p is loc ate d directly be low the handle bar . Use e ither lea ded or unlea ded gasoline with a minimum pump oc tane number of 87=(R+ M/2) octa ne. Fuel Fil ter The f uel valve has a n inter nal fuel f ilter . Do not attempt to clea n the fue l filter . See your Polaris dea ler for se[...]

61 FEAT URES AND CONTROL S Manual S hift Shif t Pedal The gear sh ift p edal i s locat ed in fro nt of th e left-h and footpe g. One full stroke of the peda l shifts the tra nsmission to th e nex t g ear in th e shi ft in g s equen ce. T he ped al automa tically r eturns to a hor izontal position whe n rele ase d. T o upshif t to a highe r gear , p[...]

62 FEAT URES AND CONTROL S Manual S hift Shi fting G ea rs NOT E: A lways allow a c old engine to war m up bef ore shif t ing gears. 1. W hen sta rting from a stopped position, plac e the tra nsmission in neutral. 2. S q ueeze and ho ld th e brake l ever . NOT E: Do not squeez e the t hrot t le lever . 3. S q ueeze t he cl ut ch l ever t o di sen g[...]

63 FEAT URES AND CONTROL S Manual S hift Rever se Lock - Out Swit ch The rev erse l ock -out sw it ch (1 ) pre vents the operator f rom shifting into r eve rse unintentiona lly . 1. Plac e the t ra nsmission in first gear . See page 61. 2. Rotate the loc k-out switch forw ard to unlock the tra nsmission. 3. S h ift in to revers e gear . NOT E: T he[...]

64 FEAT URES AND CONTROL S Manual S hift Deceler atio n T o slow or stop the A TV , re lease the throttle le ver and apply the bra kes smoothly a nd eve nly . As t he vehic le slows and e ngine RPM de crea ses, dise ngage the clutch a nd shift t o a lo wer gear . NOT E: B e sure t he engine RPM has suff icient ly decr eased bef ore shif t ing to a [...]

65 OPERATION Fuel Safety W ARNING Gas oline is highly f lamm able and explosiv e under cer tain c onditions . S Always exerc ise ext rem e caut ion whenever handling gas oline. S Always ref uel with t he engine st opped, and outdoor s or in a well v entilat ed area. S Do not s moke or allow open flam es or spark s in or near the ar ea where ref uel[...]

66 OPERATION Br eak - In Period Car eful tre atment of a n ew engine and tr ansmission will r esult in more ef fic ient per for manc e and longer life f or both. The brea k-in period for your new Polar is P re dator is def i ned as the first one hour of opera tion, or the time it takes to use the first full tank of gasoline . Follow the bre ak-in p[...]

67 OPERATION Br eak - In Period 1. Fill the fuel tank with gasoline . See page 60. 2. Check t he oil level o n the dipsti ck. S ee page 103. Add oi l if necessary t o maintai n the lev el bet ween th e safe and add m arks. 3. Allow the engine suf ficient time to war m up be fore oper ating. 4. Dr ive slowly at fir st. S ele ct an open a rea that al[...]

68 OPERATION Pr e - Ride Insp ection W ARNING If a proper inspect ion is not done bef ore each us e, s evere injur y or death c ould result . Always inspect t he vehicle bef ore eac h use t o ensure it ’s in proper oper ating condit ion. Pre - Ri de Chec kl is t Item Remarks See Page Brake system / l ever tr avel Ensure proper oper ati on 55, 141[...]

69 OPERATION Pr e - Ride Insp ection Pre - Ri de Chec kl is t Fram e nut s, bolts, f astener s Inspect , ensure ti ghtness -- Fuel and oil Ensure proper l evels 103 Coolant l evel (i f applicabl e) Ensure proper l evel 11 4 Coolant hoses (i f appli cable) Inspect f or leaks -- Th ro ttle Ensure proper oper ati on 52, 155 Indi cator l ights / swit c[...]

70 OPERATION St ar ting a Col d Engine The e ngine ca n be started whe n the transmission is in neutra l, or while in gear if the c lutch is disenga ged. W ARNING Engine exhaus t c ontains poisonous c arbon monox ide and can caus e loss of consc iousness result ing in sev ere injury or deat h. Nev er run an engine in an enclosed ar ea. CAUTION Oper[...]

71 OPERATION St ar ting a Col d Engine 2. Sit on the A TV and pull the choke knob (1) out until it stops. NOT E: I f the k nob doesn’t st ay where pos itioned, incr ease t he tens ion by rot at ing the t ension adjus ting nut cloc kwise. NOT E: T he var iable choke is fully on when the k nob is pulled complet ely out . The c hoke is off when the [...]

72 OPERATION St ar ting a Col d Engine NOT E: I f st art ing the engine while in neut ral, t he neutr al indicat or light s hould be on. I f it isn’t , dis engage the c lutc h and shif t t he f oot pedal t o f ind neutr al. See page 61. If st art ing t he engine while in gear , apply the hand br ake and squeez e the c lutc h lever f ully t o dise[...]

73 OPERATION St ar ting a W arm E ngine Follow the procedur e for starting a cold engine , but do not use the choke. If the e ngine has coole d to a point where it does not read ily start, intermitte nt use of the choke (pulled hal f way out) may be necessary . If you belie ve the engine is over -c hoked when war m, push the choke le ver comple tel[...]

74 OPERATION Driving Safely Drivin g Procedures 1. Sit upright with both fee t on the f ootpegs a nd both hands on the handleba rs. 2. Start the e ngine and a llow it to wa rm up, then shift the transmission into gea r . S ee pa ge 62. 3. Chec k your surr oundings and deter mine your path of tra vel. 4. Rele ase the par king br ake . 5. Slowly depr[...]

75 OPERATION Driving Safely Makin g T urn s Y our A TV is equipped w ith a solid r ea r axle , which drive s both rea r whe els equally at all times. The whe el on the outside of the turn trav els a great er di st ance t han th e in si de wh eel wh en t urni ng , and the inside tire slips tra ction slightly . T o turn, ste er in the dir ection of t[...]

76 OPERATION Driving Safely Drivin g on Slipper y Surfaces Whenev er ridi ng o n sl ip pery su rfaces su ch as wet t rail s or lo os e grav el, or du rin g freezin g weath er , fol lo w thes e precaut io ns : 1. Slow down when e ntering slipper y area s . 2. Ma intain a high leve l of a lertness, re ading the tr ail and avoiding quic k, shar p turn[...]

77 OPERATION Driving Safely Drivin g Uphill Whe never tr aveling uphill, follow these pr ecauti on s: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ maximum) . 3. Kee p both feet on the footpegs a nd transf er your weight for ward. 4. P ro ceed at a st eady rat e of speed an d th ro ttle opening. 5. B e alert an d prep ared to t a[...]

78 OPERATION Driving Safely Drivin g Across Hills W ARNING Im properly cros sing hills or tur ning on hills can r esult in loss of c ontrol or vehic le overt urn, res ulting in s evere injur y or deat h. Avoid cross ing the s ide of a hill when possible. F ollow proper pr ocedures as out lined in the owner ’ s manual. If you e nter into a situa t[...]

79 OPERATION Driving Safely Drivin g Downh ill Whe never de scending a hill, follow these precau ti on s: 1. P ro ceed di rectl y dow nh ill. 2. T ransf er your weight to the rea r of the vehicle . 3. Slow down. 4. Shift to the lowest gear possible while mainta ining a safe spe ed. 5. Apply the foot brake slightly t oa i di ns l o w i n g . W ARNIN[...]

80 OPERATION Driving Safely T urni ng Around on a Hill W ARNING Im proper hill c limbing proc edures c ould cause los s of cont rol or ov ert urn and res ult in serious injury or deat h. Avoid climbing s teep hills (25 _ maximum). Use e xt reme caut ion when operat ing on hills, and follow pr oper operat ing proc edures out lined in t he owner ’s[...]

81 OPERATION Driving Safely T urni ng Around on a Hill 5. Staying uphill of the A TV , t urn the handle bar s full left . Reach acro ss t he han dl ebar and app ly t he front br ake s to unlock the park br ake. 6. W ith the front brake s a pplied, pull in the clutch leve r . Use the brakes to slowly allow the vehicle to roll a round to your r ight [...]

82 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible. If it’ s una voidable, fol lo w th ese p recaut ion s: 1. T urn the engine of f. 2. Plac e the t ra nsmission in firs t gear . 3. Lock the par king brake . 4. Always bloc k the re ar whe els on the downhill side. See illustra tion. 5. Shut of f[...]

83 OPERATION Driving Safely Dr iving Over Obst acles Be al ert ! Loo k ahead an d learn t o read th e terrai n you’r e tra veling on. Be consta ntly aler t for hazard s such as l og s, ro cks and l ow han gi ng bran ches . W ARNING Sever e injury or death c an result if your vehicle c omes in c ontac t wit h a hidden obst acle. Not all obs tac le[...]

84 OPERATION Driving Safely Driv ing Through W a ter Y our A TV can ope rate thr ough water w ith a maximum re commende d depth e qual to the leve l of the footpe gs (1). Follow these proce dures when ope rating through wate r: 1. Dete rmine water de pths a nd curre nt bef ore cr ossing. 2. Choose a crossing wher e both ba nks have gra dual incline[...]

85 OPERATION Driving Safely Driv ing Through W a ter CAUTION Major engine dam age can res ult if t he vehicle is not thor oughly inspec ted af ter operat ion in water . Per for m t he serv ices out lined in t he maint enance char t. If your vehicle bec omes immer sed or is operat ed in water that exc eeds t he foot peg level, tak e it t o your deal[...]

86 OPERATION Driving Safely Dr iving in R everse Fo ll ow t hese precau ti on s when op erati ng i n reverse: 1. A void bac king downhill. 2. Bac k slowly . 3. Apply the brakes lightly for stopping. 4. A void turning at shar p angles. 5. Ne ver open the throttle suddenly while bac king.[...]

87 OPERATION Driving Safely Dr iving in R everse W ARNING Failur e to us e caut ion when operat ing in rever se can r esult in serious injury or deat h. Bef ore shif t ing into r evers e, alway s chec k f or obst acles or people behind t he vehicle. Drive s lowly . Avoid backing on inclines . Avoid t urning at sharp angles . NOT E: T his P olaris A[...]

88 EMI SSION CONTROL SYST EMS Noise Em ission Cont r ol System Do not modify the engine , intake or exha ust compone nts, as doing so ma y af fec t complia nce with U.S.A. EP A noise c ontrol re quirements ( 40 C FR 205) and loca l noise leve l require ments. Operation on Public La nds in th e U.S .A. Y o ur Po lari s veh icl e has a spark arres to[...]

89 EMI SSION CONTROL SYST EMS Cr an kcase Em ission Cont rol S ystem This engine is equipped w ith a close d cr ankc ase system. Blow-by ga ses ar e forc ed bac k to the combustion cha mber by the intake system. All exha ust ga ses exit through the exhaust system. E xhaust E mi ssi on Contr ol Syst em The emissions fro m t he exha ust of this vehic[...]

90 MAINT ENANCE AND LUBRICATION P er iodic Mai ntenance S chedule Care ful periodic mainte nance will help kee p your vehicle in the safe st, most relia ble condition. Inspe ction, adjustment a nd l ubric a tion of important compone nts are e xplaine d in the following pages. A tool kit is provided in the storage compa rtment under the sea t. T ool[...]

91 MAINT ENANCE AND LUBRICATION P er iodic Mai ntenance S chedule Mainte nance inte rvals in the f ollowing char ts are ba sed upon ave rage riding c onditions and an a vera ge vehic le spee d of approxima tely 10 miles pe r hour . V ehicle s subje cte d to sever e use must be i nspec ted and servic ed more fre quently . Recor d maintena nce and se[...]

92 MAINT ENANCE AND LUBRICATION P er iodic Mai ntenance S chedule W ARNING Im properly perf orming t he proc edures m ark ed with a J c ould result in com ponent failur e and lead to s erious injur y or deat h. Have an aut horized P olaris dealer perf orm these servi ces. Mai ntena nce Chart Key " Perfo rm t hes e proced ures mo re frequen tl [...]

93 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) Br ake syst e m s/fl ui d -- Pre- Ride -- Ins pec t; maint ain fluid lev el between fill lines Ti r es -- P re-R ide -- Ins pec t Wheels /lug nuts -- Pre- Ride -- Ins pec t; tight en Frame fas t e[...]

94 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) Engine s top s witc h -- Pre- Ride -- C hec k operation " Steer ing -- Pre- Ride -- C heck f or free oper ation and loos e c ompo- nents " Air box s ediment tubes -- Pr e-Ride -- D rain [...]

95 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) " E Air filter , main element -- W eek ly -- Ins pect ; replac e as needed J Brak e pad w ear 10 H Monthly 100 (160) Inspec t periodic ally " Oil C hange 10 H 6M 100 (160) Perf orm break[...]

96 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) Car buretor f loat bowl 50 H 6M 500 (800) Dr ain bowl periodic ally and pr ior to s torage J E Thrott le Cable/E TC Switch 50 H 6M 500 (800) Ins pec t; adjus t; replac e if nec ess ar y E Chok e ([...]

97 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) " F A-Arm (A) 50 H 3M 500 (800) Ins pec t; tighten fas tener s ; greas e (als o af- ter w as hing A TV or dr iv ing in water ) " F Rear ax le/ Rear ec c entric ( B) 25 H 3M 250 (400) Ins[...]

98 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) Coolant s tr ength 50 H 6M 500 (800) Ins pec t st rength s eas onally ; pres s ure tes t s ys tem annually Co ol an t syste m p re ssur e te st 100 H 12 M 1000 (1600) Pr essu re te st system annua[...]

99 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) Radiator 100 H 12 M 1000 ( 1600) Inspec t; c lean ext ernal s urfac e; c hange c oolant ev ery 2 y ears " Co ol in g syste m h ose s 100 H 12 M 1000 (1600) Ins pec t Engine mounts 100 H 12 M [...]

100 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Record Use t he fol lo win g chart t o record peri odi c mai nt enance. Mai ntenance Int erval Perf orm ed Se rv icin g Date Se rv icin g Dealer or Person Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.[...]

101 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Record Mai ntenance Int erval Perf orm ed Se rv icin g Date Se rv icin g Dealer or Person Remarks[...]

102 MAINT ENANCE AND LUBRICATION Lubr ication R ecomm endations Perf ormance Syn th etic 4 - Str oke (PS- 4) Oil Polar is highly re commends the use of Polar is PS- 4 or a simila r oil de signed for use in 4-str oke ma nual c lutch A TV and motorc ycle a pplica tions. PS-4 has bee n specific ally for m ulate d for use in high pe rfor m an ce engine[...]

103 MAINT ENANCE AND LUBRICATION Engine Oil Level Ch eck t he o il lev el b efore each us e of t he veh icl e. The dipstic k (1) is loca ted on the left side of the A TV . 1. Position the A TV on a level surf ace. 2. Start the engine a nd le t it idle for one minute . 3. Stop the engine and remove the dipstic k. W ipe it dry with a cle an cloth. 4.[...]

104 MAINT ENANCE AND LUBRICATION Engine Oil Level If the A TV is used ye ar -round, ch ec k the oil leve l fre quently . A rising oil le vel c ould in di cate t he accu mu lat io n o f cont am in ates su ch as wat er o r excess fuel i n t he bo tt om of th e oil tank. W ate r in the bottom of the tank c an le ad to engine da mage a nd must be dr ai[...]

105 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e CAUTION If t he A T V is left wit hout oil i n the syst em f or ext ended periods, the oi l pump may lose its prime, which c ould result in engine dam age. Do not allow the v ehicle t o be without oil and filt er ov ernight . A lways r eplace t he oil and filt er wit hin a few hour s of drai[...]

106 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 1. P l ace th e vehi cl e on a l evel su rface. 2. Clea n the are a around the oil tank (1) and crankcas e (2) drai n pl ugs wi th cl ean sh op towe ls. 3. Run the engine for two to three minutes until warm, then stop the engine . 4. Place a dr ain pa n benea th the oil tank and re move the [...]

107 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 7. Place a dr ain pan benea th the cr ankcase a nd remove the dra in plug. 8. Allow the oil to dra in complete ly . 9. Repla ce the se aling washe r and re install the plug. T orque to 14 f t. l bs. (19 Nm). 10. Place shop towe ls be nea th the oil filter . 1 1. Remove the three cove r bolts[...]

108 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 16. Reinstall the spr i ng an d install the ne w filter with the ope n end fa cing outwar d. 17. Install the c over a nd torque the bolts to 72- 78 in. lbs. (8-9 Nm). NOT E: T he long bolt must be placed in t he f orward hole. 18. Remove the dipstick a nd fill the oil tank w ith the rec omme[...]

109 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 20. Pr ime t he oil pump using the pr oc edur e on page 1 10 . Then stop t he engine a nd in sp ect for l eaks . 21. Re-che ck the oil le vel on the dipstic k and add oil a s ne ce ssary to bring the leve l to the upper mark on the dipstick. 22. Dispose of the use d filter , oil and shop tow[...]

11 0 MAINT ENANCE AND LUBRICATION Oil Pump Pr iming This priming proc edur e m ust be perform ed wh enever t he o il hos e con necti on b etween t he oi l t ank and pump inlet has be en disconnec ted. 1. Clamp or pinch of f the vent line (1) a pproxima tely 2 I (5 c m ) f rom the oil tank. 2. Run the engine for 5-10 sec onds at idle . Stop the engi[...]

111 MAINT ENANCE AND LUBRICATION Air Filter System s 1. Unlatc h and remove the sea t. 2. Loosen the intake duct cla mp (1) on the ca rbure t or . 3. Pull the duct ( 2) of f the carbur etor . 4. Rele ase the eight airbox cove r clips (3) and re move the cove r (4). 5. Re move the air f ilter (5). Inspe ct and re plac e if neces sary . 6. Re move th[...]

11 2 MAINT ENANCE AND LUBRICATION Air Filter System s 7. Re install the air filte r . 8. Reinsta l l the airbox cover a nd se cur e the clips. 9. Reinsta l l the intake duct to the carbur etor and secur e the clamp. 10 . C heck t he hoses for cracks, d eteri orat i on, ab rasi on, o r leaks . R epl ace as need ed. CAUTION Oper ation of your vehicle[...]

11 3 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem The engine c oolant level is controlled or mainta ined by the recove ry system. The rec overy system compone nts a re the rec overy bottle, rad iator f iller ne ck, radia tor pressure c ap and conne cting hose. T o ensure tha t the coola nt m ainta ins its ability to protec t the e ngine, w[...]

11 4 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem Co olant L evel The re cover y bottle (1) is l oca ted on the le ft side of the mac hine under the front fende r . The fluid level must be mainta ined betw ee n the minimum and maximum ma rks on the bottle (whe n t he fluid is cool). As co olan t o perat in g t emperat ure i ncreas es, t he[...]

11 5 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem W ARNING Esc aping st eam can c ause sev ere burns . Nev er rem ove t he press ure cap while t he engine is warm or hot . A lways allow t he engine t o cool bef ore rem oving t he cap. Rad iato r Coo lant Level This proce dure is re quired only if the c ooling system has bee n drained f or [...]

11 6 MAINT ENANCE AND LUBRICATION Lights Whe n servic ing a ha logen la mp, don’t touc h t he la mp with bare f ingers. Oil from your skin lea ves a residue , causing a hot spot that will shorten the life of the lamp. W ARNING Poor light ing while driv ing can res ult in s evere injur y or deat h. Headlight and t aillight lenses bec ome dirt y du[...]

11 7 MAINT ENANCE AND LUBRICATION Lights Head light L amp Rep lacement 1. Remove the wir e harness conne ctor from the bac k of the he adlight. 2. On the le ft headla mp, grasp the bulb housing and turn it c ounter clock w ise (1) to remove the bulb. On the right he adlamp, turn the bulb housing clo ckwi s e (2) to remove the bulb. 3. Ap pl y di el[...]

11 8 MAINT ENANCE AND LUBRICATION Lights Head light A ssembly Replacem ent 1. Remove the wir e harness conne ctor from the hea dlights. 2. Remove the fr ont ca b (se e page 122). Position the ca b upside down on a soft pro tect iv e su rface to preven t s cratch in g. 3. Re move the small adjuste r brack et (1) and install it on the new la mp. 4. R[...]

11 9 MAINT ENANCE AND LUBRICATION Lights Head light A ssembly Replacem ent 5. Insta ll the ne w headla mp by inserting the outboa rd pivot pin in the hole of the mounting tab on the c ab. 6. Insta ll the adjuste r bracke t onto the inboard pivot pin of t he hea dlamp. 7. Adjust for appr oximate ly 1/16” cle aranc e betwee n the br ac ket and the [...]

120 MAINT ENANCE AND LUBRICATION Lights Head light Ad justmen t 1. Position the A TV on a level surfa ce with the hea dlight approximate ly 25 ft. (7.6 m ) f rom a flat wa ll. 2. Mea sure the distanc e fr om the floor to the c enter of th e headl i ght and mak e a mark on t he wal l at t he same he ight. 3. Start the engine and turn the hea dlight [...]

121 MAINT ENANCE AND LUBRICATION S ide P anel Rem oval 1. Unlatc h and remove the sea t. 2. Remove the four sc rews (1) secur i ng the side pane l. 3. Remove the side pa nel. Rear Cab Removal 1. Unlatc h and remove the sea t. 2. Remove the f our bolts (2) on t he re ar fe nder s of the c ab and the two bolts ( 3), washe rs and gromme ts (4) on the [...]

122 MAINT ENANCE AND LUBRICATION Fr ont Cab Re m oval 1. Remove the scr ews and washers (1) fr om th e front l eft-han d and ri ght -han d cab mounts. 2. Remove the wir e harness conne ctor from the hea dlights. 3. L oos en t he s crew (2) l ocat ed i ns id e th e cab under the front cove r . 4. Gently pull the c ab forw ard to remove the ca b a nd[...]

123 MAINT ENANCE AND LUBRICATION S par k Plugs S Use NGK DC PR 8E spark plugs. S Proper ele ctrode gap is . 035 ″ (.90 mm). S Spark plug torque is 14 ft. lbs. (19 Nm) . CAUTION Using non-r ecomm ended spark plugs m ay res ult in s erious engine dam age and may void your emiss ion-relat ed warr anty . Alway s use P olaris- recom mended spar k plug[...]

124 MAINT ENANCE AND LUBRICATION S par k Plugs 1. Normal The norma l insulator tip is gra y , tan or light brown. There will be fe w combustion deposits. The ele ctrodes are not burne d or er oded. This indic ates the prope r t ype and hea t ra nge for the engine a nd the ser vice. NOT E: T he t ip should not be white. A whit e insulat or t ip indi[...]

125 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 1. Remove the side pane ls and fr ont ca b (se e pages 121-122). 2. T urn the fuel valve to OF F . W ARNING A hot ember on t he A T V c ould cause f uel t o ignite. Allow all c omponent s t o cool suffic iently befor e acces sing t he spark plug. A lways ex ercis e [...]

126 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 3. Move the fue l va lve hose cla mp (1) for war d and gently remove the hose fr om the fue l valve fitting on t he gas tank. 4. Remove the ve nt hose (2) from the instrume nt pane l, taking note of the hose routing for r einstalla tion. 5. Remove the ta nk mounting[...]

127 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 7. Using the fo rked e nd of the spar k plug wrench handle , remove the spa rk plug boot. IMPOR T ANT : Do not pull on the wire to re move the boot. Doing so may cause a w ire disconne ction inside t he boot. 8. Using the spa rk plug wre nch a nd handle, rotate coun[...]

128 MAINT ENANCE AND LUBRICATION Spar k Ar restor Cl ean - Out W ARNING Do not per for m clean- out im mediat ely af ter the engine has been r un, as the exhaust system becomes very hot . Seri ous burns could result fro m cont act wit h the exhaust component s. Wear eye prot ect ion and gloves . Never r un the engine in an enc losed area. Ex haust [...]

129 MAINT ENANCE AND LUBRICATION Spar k Ar restor Cl ean - Out Peri odical ly cl ean th e spark arre stor t o remove accu m ulated carbon. 1. Remove the thre e screws (1) a nd remove the a rre stor (2) fr om the end of the muff ler . 2. Use a non-synthe tic brush to cle an the arr estor sc reen (3) . A synthetic brush may melt if compone nts a re w[...]

130 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n If your A TV has be en submer ged or overtur ned in water dee per than the f ootpeg level, it’ s cr itical to dry it pro mptly and pr operly be fore sta rting the engine . CAUTION Do not s tar t t he engine af ter an A T V has been in wat er t hat exceeds the recom mended dept h. S erious [...]

131 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n W ARNING Fluids will be eject ed thr ough the s park plug hole and m ay caus e serious injury to f ace or ot her body par ts . S tand c lear of the s park plug while per for ming t he following st eps. 5. In ter mittently and br iefly touc h t he sta rter button in h alf -se cond inter vals [...]

132 MAINT ENANCE AND LUBRICATION Batter y The sea led batte ry is alr eady f illed with e lectr olyte a nd has be en sea led and fully char ged at th e facto ry . N ever pry the se aling strip of f or add a ny other f luid to this batter y . Keep bat tery t ermi nal s and con nect io ns free of corros io n. If clean ing i s neces sary , remo ve the[...]

133 MAINT ENANCE AND LUBRICATION Battery Installation 1. Set the ba ttery in the b attery holde r . 2. Conne ct a nd tighten the re d (positive) c able f i rst, then c onnect a nd tighten the blac k (neg ati ve) cabl e. 3. At t ach the ho ld -do wn st rap and rei ns tal l t he rear cab. 4. V erify tha t cab les a re proper l y route d. NOT E: W hen[...]

134 MAINT ENANCE AND LUBRICATION Batter y Charging (S ealed Batter y) The most impor tant pa rt of ma intaining a sea led batte ry is keep ing it fully cha r ged. The ba ttery include d with your A TV is sea l ed a nd the sea ling strip c annot be r emoved. Use a voltmete r or multimeter to me asur e DC voltage. A fully c har ged batte ry will regi[...]

135 MAINT ENANCE AND LUBRICATION Batter y Charging (S ealed Batter y) NOT E: A lways v erif y bat ter y condit ion bef ore and 1-2 hour s af ter charging. Stat e of Charge Vo l t a g e Action Char ge Ti me* (Us ing cons tant cur rent char ger @ standar d amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. fr om date of m[...]

136 MAINT ENANCE AND LUBRICATION Tire s W ARNING Oper ating y our A T V wit h worn t ires , im properly inflat ed t ires, non-s tandar d tir es or improper ly inst alled t ires will aff ect vehicle handling and c ould cause an ac cident result ing in ser ious injury or deat h. Maint ain proper t ire pr essur e as desc ribed on t he A T V decal and [...]

137 MAINT ENANCE AND LUBRICATION Ti re T read Depth Always re place tires whe n tread de pth i s worn to 1/8 ″ (.3 cm) or le ss. See illustr ation. Wheel Rem o val 1. Stop the engine, place the tr ansmission in gear a nd lo ck th e parki ng brak e. 2. Loosen the whe el nuts slightly . 3. Elev ate the side of the veh icle by plac ing a suita ble s[...]

138 MAINT ENANCE AND LUBRICATION Wheel Installation W ARNING Im properly inst alled wheels can adv ersely affect t ire wear and v ehicle handling, which can res ult in s erious injur y or deat h. Always ensur e that all nut s are t orqued t o specif icat ion. Do not s ervic e axle nut s t hat hav e a cot ter pin inst alled. See y our Polaris dealer[...]

139 MAINT ENANCE AND LUBRICATION Wheel Nut T orque Specifications Ch eck th e wheel n ut t orq ues occas io nal ly an d when t hey ’ve been l oo sened fo r mai nt enance serv ice. Bol t Si ze Sp ecif icat io n Fr ont 3/8 ″ 27 f t . lbs . ( 36.5 Nm ) Rear 3/8 ″ 27 f t . lbs . ( 36.5 Nm )[...]

140 ADJUST MENTS Br akes Under normal ope ration, the d iaphr agm e xtends into the rese rvoir as fluid leve l drops. If the f luid leve l is low and the diaphra gm is not exte nded, a leak is like ly and the dia phra gm should be replaced. Always fill the reservoi r as needed when ever the cover is loosened or re moved to ensure pr oper dia phragm[...]

141 ADJUST MENTS Br akes 1. Always mainta in the brake fluid at an ade quate level (see pa ge 56). 2. C heck th e brake s ys tem for f lui d l eaks . 3. Chec k the bra kes for exce ssive trave l or spongy fe el. 4. C heck t he fri cti on pad s for wear , d amag e and lo osen ess . 5. Che ck the sec urity and sur fa ce condition of the disc . 6. In [...]

142 ADJUST MENTS W ARNING Sever e injury or death c an result f rom im proper toe alignm ent and adjus tm ent. Do not att empt t o adjust tie r od alignment . All tie r od adjust ments should be per for med by an author ized Polar is dealer . T oe Alignm ent Use the following proce dure to check the toe alignme nt of the vehic le. The Preda tor is [...]

143 ADJUST MENTS T oe Alignm ent 3. T ie an elastic str i ng (2) ar ound the stands, ma king sure the string just touches the side surfa ce of the rear ti res on each si de o f th e veh icl e and g oes ar ound the sta nds in front of the vehicle . 4. Mea sure the distanc e from the string to the rim at the f ront and re ar of the fr ont rim (3). Th[...]

144 ADJUST MENTS Chain T ension CAUTION Never adjus t or operat e the v ehicle wit h the r ear driv e chain t oo loose or t oo t ight. Sever e damage t o the t rans miss ion and drive c omponent s can r esult . Chain t ension must be inspec ted wit h t he swing arm in the pos ition s hown in the illus tr ation s o that the ax le, s wing arm piv ot [...]

145 ADJUST MENTS Chain T ension Chec k the amount of c hain sla ck by moving the ve hicle slightly for ward to r emove slac k at the top side of the chain. NOT E: T he chain has a press -on mas ter link. A chain t ool mus t be us ed if it ’s necessar y to r emove t he chain f or s ervic e. 1. Collapse the suspe nsion with an a djustab le (buc kle[...]

146 ADJUST MENTS Chain T ension 1. L oos en th e two eccent ric l ocki ng b olt s . 2. Insert a pin punch into t he eccentri c ax le housing. 3. Roll the ve hicle a head or bac k to adjust cha i n slac k to the prope r dimension. 4. T i gh ten t he eccent ric l ocki ng b ol ts t o 35 ft . l bs . (4 7. 5 Nm ). Step 1 Proper Spl icel ink Cli p Openin[...]

147 ADJUST MENTS Steer in g Assem b ly The ste er ing assembly of the A TV should be c hecke d periodica lly for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dea l er f or s er vice befo re ope ra ting the vehic l e. Cam b er and Caster The ca m ber a nd c aster ar e non-adjusta ble.[...]

148 ADJUST MENTS Suspension Settings Use a f lat blade sc rewd rive r (in tool kit) to make damping adjustme nts. NOT E: W hen t he adjust er sc rew is t urned c lockwis e until it st ops, t he damping is in t he fully closed pos ition. Rear Sh ock (St andard an d T roy Lee) Se ttin g Compr ession Dampi ng Rebound Dampi n g So fte st 20 clicks f ro[...]

149 ADJUST MENTS Fr ont Suspens ion Co mpression D amping ( T roy Lee) T o adjust the front suspension compre ssion da mping, use t he adjustme nt proc edure s outlined f or the r ear suspe nsion compre ssion damping on page 153. Spring Prelo a d The f ront suspension pr eload may be adjuste d to suit dif fe re nt riding conditions a nd oper ator w[...]

150 ADJUST MENTS Fr ont Suspens ion Spring Prelo a d 1. Raise a nd safe ly support t he fr ont of the A TV of f the ground to a llow the suspension to fu lly exte nd. 2. Loosen the jam nut (1) . 3. T urn the a djusting ring (2) to the left to incr ease pre load (A) . T urn the ring to the right to de crea se preloa d (B). 4. T ighten the ja m nut a[...]

151 ADJUST MENTS Rear S uspen sion The re ar suspension spr ing preload, shock re bound damping and shoc k compre ssion damping ma y be a djusted to suit dif fer ent riding conditions a nd operator we ight. Spring Prelo a d 1. Raise a nd safe ly support t he re ar of the A TV off the ground to a llow the suspension to fu lly exte nd. 2. Loosen the [...]

152 ADJUST MENTS Rear S uspen sion Rebound Da mping 1. Loca t e the re bound damping cli cker d rum bet ween th e lo wer spring sea t and the lowe r shock mount. 2. Use a scr ewdrive r make the adjustme nt. T urn the clicke r counte r- clockwise to dec rease the rebound da mping (A). T urn the clic ker cloc kwise to incre ase re bound damping (B) .[...]

1 A B 153 ADJUST MENTS Rear S uspen sion Co mpression D amping The c ompression damping c licker ( 1) is locate d on top of the shock rese rvoir , under the right rear fe nder . Use a sc rewdr iver to make adjustme nts. T o incre ase compr ession damping, turn the clicker c lockwise (A ). T o dec rease c ompression damping, turn the clicke r counte[...]

154 ADJUST MENTS Clutch Lever Freeplay 1. M easu re clut ch lev er freeplay b etween the per ch and the leve r (A). This distanc e should be 1/8 ″ -3 / 1 6 ″ (3.1 mm - 4 .7 mm). 2. If a djustment is r equir ed, slide the clutch pe rch pivot boot down the clu tch cabl e to access th e clu tch adjustme nt scre w (B) a nd lock r ing (C). 3. L oos [...]

155 ADJUST MENTS Thr ottle C able Fr eeplay W ARNING Im proper adjus tm ent of t hrot tle c able fr eeplay can r esult in loss of cont rol, which c ould result in serious injur y or death. Polar is rec ommends t hat t his procedur e be perform ed by a Polar is dealer t o ensur e that it ’ s done corr ect ly . M echanically knowledgeable persons w[...]

156 ADJUST MENTS Handlebars If des ired, t he h andl ebars can be ad ju st ed for ri der p reference. W ARNING Im proper adjust ment of t he handlebars or incorr ect t orquing of the adjuster block bolt s can caus e limit ed st eering or loos ening of t he handlebars , whic h could res ult in los s of cont rol and serious injury or deat h. F ollow [...]

157 ADJUST MENTS Ca r buretor /Idl e RP M If the e ngine idle spee d is not satisfac tory , and all other conditions ar e fa vora ble, the carbur etor can be adjuste d. 1. W arm up the engine by running the vehicle f or five minute s , or u nt il operat i ng t emp eratu re is reached . 2. Apply the pa rk brake and pla ce the tr ansmission in neutra[...]

158 ADJUST MENTS Ca r buretor /Idl e RP M Car buretor r e- j etting c an be pe rforme d to compensa te for altitude a nd/or tempe rature cha nges. If the veh icle is to be opera ted at various altitude s a nd te mperatur es, certa in adjustme nts can be ma de to improve its opera tion and drive ability . Above 6000 f ee t (1800 m) the engine a i r/[...]

159 CLEANING AND ST ORAGE See page 173 for the pa rt numbers of Polaris products. Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of var ious components. W ash ing th e A TV CAUTION Do not us e a high press ure washer for washing t he A T V . Ser ious damage will r esult to wheel[...]

160 CLEANING AND ST ORAGE W axing the A TV Y our A TV can be waxe d with any non-a brasive au tomotive paste wa x. A void the use of har s h cle aner s since they c an scr atc h t he body f i nish. CAUTION Cert ain product s, including ins ect repellant s and chem icals, will damage plas tic surf aces . Us e caut ion when using t hese produc ts nea[...]

161 CLEANING AND ST ORAGE See page 173 for the pa rt numbers of Polaris products. St or age Recom me ndations CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm c reat ed by fogging and dam age could occ ur . Nev er st art the engine dur ing the s tor age period. Clean t he Exterio r Make nece ssary re [...]

162 CLEANING AND ST ORAGE St or age Recom me ndations Oil and Filt er W ar m the engine and cha nge the oil a nd filter . See pa ge 105. Air F ilter / Air Bo x Inspe ct and c lean or re place the pr e-c lea ner a nd air f ilter . Clea n the air box a nd dra in the sedime nt tube. Br eath er Filter Inspe ct and clea n or re place the br eathe r filt[...]

163 CLEANING AND ST ORAGE See page 173 for the pa rt numbers of Polaris products. St or age Recom me ndations Fog the E ngine 1. Start the engine and allow it to warm up. T urn engine of f. 2. Unlatc h and remove the sea t. 3. Loosen the intake duc t cla mp at the carbur etor and pull the duct of f the car buretor . 4. Start the engine and spra y P[...]

164 CLEANING AND ST ORAGE St or age Recom me ndations Inspe ct a nd Lubric ate Ins pect al l cabl es and l ub ricat e. F ol lo w lub ri cati on g uid eli nes i n th e Main ten ance Sect i on of the servic e or owner ’ s manual to completely gre ase and lubrica te the entire ve hicle with P olari s P remi um Al l S eason Greas e. Engi ne Anti - Fr[...]

165 CLEANING AND ST ORAGE T ranspor ting the A TV Follow these pr ocedure s when transpor ting the vehic l e. 1. T urn of f the engine and re move the key to pre vent loss during tra nsporting. 2. T urn the fuel valve of f. 3. B e su re th e fuel cap, o il cap an d seat are installe d corr ectly . 4. Alwa ys tie the frame of the A TV to the tra nsp[...]

166 TROUBLESHOOTING Contact your Polaris dea ler for ser vice if you’ re una ble to identify solutions using the follow ing cha rts. Eng ine Doesn ’t T urn Over Po ssibl e Cause Sol uti on Fu seab le lin k S ee Po laris d ealer fo r rep lacemen t Lo w b attery v o ltag e Re cha r ge ba tt er y to 12. 8 VDC Loos e ba tte r y conne ct ions Ch eck[...]

167 TROUBLESHOOTING Eng ine T urns Over , Fails t o St art Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Clogge d fue l val ve In spect an d clean or repl ace W ater is p resen t in fu el Drain t he fuel system an d refu el Fue l val ve is t urne d of f T ur n t he f ue l val ve on Ol d, poor or non- re comm e nded f[...]

168 TROUBLESHOOTING Engine P ings or Knock s Po ssibl e Cause Sol uti on Po o r q u ality o r lo w o ctan e fu el Re pla c e wit h re comme nded f uel In correct ig n itio n tim in g Se e your Pola ri s dea le r In correct sp ark plu g g ap o r heat rang e Se t ga p t o s pe c s or re pla ce plugs Eng ine Backf ires Po ssibl e Cause Sol uti on W ea[...]

169 TROUBLESHOOTING Engine Runs I rregul arl y , Sta lls or Mis fire s Po ssibl e Cause Sol uti on Foule d or def ec ti ve s par k plug In spect, clean and /o r replace spark p lu g s W orn or def e c tive s par k plug wi re Se e your Pola ri s dea le r In correct sp ark plu g g ap o r heat rang e Se t ga p t o s pe c s or re pla ce plugs Lo o se i[...]

170 TROUBLESHOOTING Engine Runs I rregul arl y , Sta lls or Mis fire s Po ssibl e Le an Fue l M ix ture Cause Sol uti on Lo w o r co n tamin ated fu el Add or cha nge f ue l, cl ea n the f uel s yst em Lo w o ctan e fu el Re pla c e wit h re comme nded f uel Ol d, poor or non-r e comme nde d f ue l Re pla c e wit h re comme nded f uel Clogge d fue [...]

171 TROUBLESHOOTING Engine S tops or Loses P ower Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Ki nked or plugge d fue l vent l ine In spect an d rep lace W ater p resen t in fu el Re pla c e wi th new f ue l Ove rus e of choke In spect, clean and /o r replace spark p lu g s Foule d or def ec ti ve s par k plug In s[...]

172 TROUBLESHOOTING Engine S tops or Loses P ower Po ssibl e Cause Sol uti on Clogge d, dir ty or wet a ir f ilter In sp ect and clean o r rep lace Electro n ic th ro ttle con tro l (E T C) m alfu nctio n Se e your Pola ri s dea le r Oth er m ech anical failu re Se e your Pola ri s dea le r Ov erh eated en g in e Cle a n r a dia tor s c re en a nd [...]

173 POLARIS PRODUCTS Part # Descr ipti on Part # Descri pti on Engine Lubr icant Coolant 2874414 Perf ormance Synt heti c 4-Str oke (PS- 4) Oil (qt. ) 2871323 60/40 Coolant ( gal. ) 2874415 PS-4 Oi l (gal .) 2871534 60/40 Coolant ( qt. ) Gr ease / Speci alized Lubri cants 2871312 Gr ease Gun Kit, Pr emi u m Al l Season ( 3 oz.) Addit ives / Miscel [...]

174 SPECIF ICATIO NS Pr edator 500 Gro ss V e hic le W eig h t 645 lbs ./292 kg Pilot J et 45 Fuel C apacity 3.25 gal ./ 12.3 l Main J et 150 Overal l Length 71.5 i n./ 182 cm Needle Je t O- OM Overal l Wi dth 47. 5 in. /121 cm J et Needle 6CGY 07 - 060 - 3 Overal l Height 45 in. /1 14 cm Al ternat or Output 200 w @ 3000 R PM Wheel base 51 in./ 130[...]

175 SPECIF ICATIO NS Pr edator 500 Driv ing Sy ste m T yp e Rear T wo - Wheel Dri v e T ire Si ze/Pressure - Front 2 1x7 - 1 0/4p s i S hif t T ype 5 - Speed Manual S hift T ire Si ze/Pr essure - Rear 2 0x1 1 - 9/4p s i( S t d ) 2 0x1 0 - 9/4p s i( T r o yL e e ) Driv e Ratio - Fin al 14/38 F ront B rake Hydraulic Disc Gear Rat io - 1 st 2.4 R ear [...]

176 WARRANTY LIM IT ED W ARRANT Y Pola ri s Sa le s I nc. , 2100 Highw a y 55, M edi na, M N 55340, give s a SIX M ONTH LIM ITED W ARRANTY on al l c omponent s of the Pol ar is Al l T er ra in V e hic le ( A TV) a ga ins t def ec ts i n mat er ia l or workm ans hip. Pola ri s al so give s a one ye ar l im it e d wa rr ant y on t he f ina l dri ve c[...]

177 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TI ONS OF W ARRANTIE S AND REMEDI ES The Pola ri s l imi te d war ra nty e xcl udes a ny fa il ure s t hat ar e not ca us e d by a def ec t i n mat er ia l or wor kmans hip. Th is w arran ty d o es n o t cov er accid en tal d amag e, n o rmal w ear an d t ear , ab u se o r imp ro p er han d[...]

178 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMI T A TI ONS OF W ARRANTIE S AND REMEDI ES ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED TO THE I MPLIED W ARRANTIES OF MERCHANT ABILITY AND FI TNESS FOR A P AR TI CULAR PURPOSE) ARE LI MITED IN DURA TION T O THE ABOVE SIX M ONTH W ARRANTY PERIOD. POLARIS FUR THER DI SCLAIM S ALL EXPRESS [...]

179 WARRANTY HOW TO OBT AIN W ARRANTY SERVICE I f your A TV r equi r e s wa rr ant y se rvi ce , you mus t t ake it to a Pol ar is dea le r a uthor iz ed t o re pai r Pol ar is A TVs. Whe n re ques ti ng wa r r a nt y s e rvi c e you mus t pr es ent your c opy of t he W ar ra nty Re gis tr a ti on for m t o the de al er . (THE COST OF TRANSPOR T A [...]

180 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORI ZED LOCA TION. Th is po licy d o es n ot app ly to v eh icles that hav e received au tho rizatio n fo r e xpor t fr om Pola ri s I[...]

181 WARRANTY Exported V ehicles How to G et S erv ic e In the C o u nt ry wh ere yo ur vehicle w a s p urch a sed : W ar ra nty or Se r vic e Bull et in r e pa ir s must be done by a n aut hori ze d Pola ri s de al er . If you move or a re tr ave li ng wi thi n the c ountr y wher e your vehi cl e w as purc has ed, W ar ra nty or Ser vic e Bul le ti[...]

182 WARRANTY Exported V ehicles How to G et S erv ic e If P urch a sed F rom A P riva te P arty: I f you purc has e a Pola ri s produc t fr om a pri vat e ci ti ze n outs ide of t he c ountr y in whic h the ve hic le wa s ori gina ll y pur c has ed, a ll wa rr ant y c over age wi ll be de nie d. Notic e I f your vehi cl e is r egi st er ed outs ide[...]

183 WARRANTY U. S.A. EP A Emi ss io n s L i mit ed W a rra nt y Th is All T errain V eh icle (A T V ) o r Off Ro ad U tility V eh icle (OR U V) emissio ns limited w arranty is in add itio n to th e Po laris stand ard limited w arran ty fo r th is v ehicle. Po laris w arran ts th at this v eh icle is; (1 ) d esig ned , b u ilt, an d equ ip p ed t o [...]

184 WARRANTY U. S.A. EP A Emi ss io n s L i mit ed W a rra nt y Th e ex clu sive rem ed y fo r b reach o f this lim ited warran ty sh all b e, at th e exclu siv e op tio n o f P olaris, rep air o r re- p lacemen t o f an y d efective m aterials, co m ponent s or produc ts . THE REMED IES SET FOR TH IN TH IS LI M- ITED W ARRANTY ARE THE ONL Y REMEDI[...]

185 Index A Adj ustme nts 140-158 ............... Air Filter System s 11 1 -112 ........... B Battery 1 32 ...................... B at tery C har ging 134-135 ............ Battery I nstallatio n 13 3 ............. B at tery R emoval 132 ............... B at tery S torage 133 ................ Brak e Fluid 5 6 .................... Brake Lever s 5 5 .[...]

186 Index L-M Light S wit ches 51 ................. Light s 50, 116-120 ................. Lubri cati on Rec ommendat ions 102 .... Mai ntena nce 90-139 ................ Mai ntena nce R ecord 100-101 ......... Maki ng Tur ns 75 .................. Manua l Shift 61-64 ................. Mas ter C yli nder 56 ................ N- O Noise Em ission Co ntr[...]