Polaris Predator 9920779 manual

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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 POLARI S and POLARIS THE W A Y OUT a r e re gi s t e r e d tr a de ma r ks of Pol a ri s I ndus t r i e s I nc . Copyr ight 2006 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 the time of pu b licatio n. Du e to con stant imp ro vem en ts in the desig n a[...]

3 WELC OM E Tha nk you for purcha sing a Polaris ve hicle, and w elc ome to our wor ld-wide family of Polaris ow ners. W e pr oudly produce a n exciting line of utility and r ecr ea tional products. 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 exce llence f or 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 ....................................................... KNOW YOUR VEHI CLE 6 ........................................... SAF ETY 8 ......................................................... FEA T URES AND CONTROLS 48 ..................................... OPE RA TION 65 ................................................[...]

6 KNOW YOUR VE HICLE As the operator of the ve hicle, you are re sponsible for your personal safe ty , the safe ty of other s, and the pr otec tion of our envir onment. Read a nd understa nd your owne r ’ s manual, which include s valuable inf ormation about a ll aspec t s of your vehicle, including sa fe oper ating pr oce dures. V ehicle I denti[...]

7 KNOW YOUR VE HICLE V ehicle I dentifica tion Num ber s V ehic le Model Number: Frame V IN ( 1)(lef t s ide): Engi ne Seria l Numbe r (2)(righ t side): Key Number ( 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 protect ion. Read and follow t he in st ruct io ns of t he decal s on t he A TV carefull y . If any o f the decal s dep ict ed in t hi s man ual differ from the decals on your A TV , al ways read and follow the inst ru cti ons of t he decal s on the [...]

9 SA FE TY Safety D ecals an d Locatio ns Ge nera l W a rning (1 ) W ARNING Im proper A TV use can resul t in SEVERE INJ U RY or D EA TH AL W A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operat e: S wit hout proper t raini ng or inst ruct ion S at speeds t o[...]

10 SA FE TY Safety D ecals an d Locatio ns A g e1 6W a r n i n g( 2 ) W ARNING Oper ating t his A TV i f you ar e under t he age of 16 incr eases your chance of severe injur y or death. NEVER oper ate t his A TV i f you ar e under age 16. Sport A TV W arning (3 ) W ARNING This A TV may exceed the per for mance of ot her A TVs you may have r idden i[...]

11 SA FE TY Safety D ecals an d Locatio ns No Passen ger W arnin g (5) W ARNING NEVER r ide as a passenger . Passengers can cause a l oss of cont ro l, resul ting i n SEVERE INJUR Y o r DEA TH. T ire Pressure/L oad W arnin g (6) IMPROPER TI RE PRESSURE OR OVERLOADI NG can cause loss of contr ol resul ting i n SEVERE INJUR Y OR DEA TH. TIRE PRESSURE[...]

12 SA FE TY Sa fe Riding Gea r Always wea r appropr iate clothing whe n riding an A TV . W ear prote ctive clothing for comf ort and to r educ e t he ch anc e of injury . 1. Helmet W ea ring a helmet can pre vent a severe he ad injury . Wheneve r rid in g a Pol aris v ehi cle, al ways wear a helm et t hat m eets o r exceeds est abl i shed s afety s[...]

13 SA FE TY Sa fe Riding Gea r 2. Eye Prot ection Do not depend on e yeglasse s or sunglasse s for e ye protection. Whe neve r riding a Polar is vehic le, alw ays we ar sha tterpr oof goggles or use a shatte rpr oof helme t face shield. Polar is re commends w ea ring appr oved Persona l Prote ctive Equipme nt (PP E) b earing m arki ngs su ch as VES[...]

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 Sa fety T r ai ning A TV sa fety tra ining is a top priority f or Polaris. When you pur chase d your new A TV , your dea l er instructed you on the aut ho rized A TV RiderCourse sm avail abl e t o you and your eligible f amily me mbers. This tra ining is included in the pur chase pric e of your A TV . Polar is strongly [...]

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 fety is involved w hen these w ords and symbols a re used. Become familia r 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 i[...]

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 t hi s m anual and al l l abel s careful ly , and f ollow the ope rating proc edures de - scr ibed. S Neve r opera te an A TV without [...]

19 SA FE TY Operator S afety S Neve r operate a n A TV on a public str ee t , roa d or highway , including a dirt or grav- el road. S Neve r opera te an A TV without wearing an a pproved helme t t hat f its prope rly . Always we ar e ye protec tion (goggles or fa ce shield), gloves, boots, a long- sl eeved s hi rt or j acket , an d lo ng pan ts . S[...]

20 SA FE TY Operator S afety S Neve r opera te on e xcessively r ough, slip- per y , or l oose ter ra in. S Always follow prope r t urning proc edures as de scribed in this manua l. Prac tice turning at low speed s befor e attempting to t urn at fas ter s peeds . Do n ot t urn at exces si ve s peeds . S Always have the A TV inspected by an aut hor [...]

21 SA FE TY Operator S afety S Always follow proper pr oce dures f or cr ossing the side of a hill. A void hills with exc essively slippe ry or loose sur- faces. Shi ft your we ight to the uphil l side of the A TV . Neve r attempt to turn the A TV around on a ny hill until you’ve maste red (on le vel ground) the tur ning tec hnique outlined in th[...]

22 SA FE TY Operator S afety S A void ope rating the A TV through dee p or fa st-flowing wa ter . If it’ s unavoid- able , t ra vel slowly , bala nce your weight ca refully , avoid sudde n m oveme nts, and mainta in a slow and ste ady for ward mo- tion. Do not make sudden turns or stops, and do not ma ke sudden throttle c hanges. S W et brakes ma[...]

23 SA FE TY Operator S afety Equipme nt Modific ati ons W e are conc erned for the sa fety 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 a ny equipment 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 for[...]

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 risk of an ac cident is great ly inc reased 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 : Sev ere injury and/or death c ould occur 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 antial [...]

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 : Sev ere injury and/or death c ould occur if a c hild 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 T[...]

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 : Carr ying a pass enger 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 T V 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, accid[...]

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 : Consum ption of alcohol and/ or dr ugs could s eriously affect 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 ore [...]

32 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : A ttemp ting j ump s and other 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 jumps or other st unts . Avoid exhibit ion driv ing.[...]

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 : Poor maint enance incr eases t he poss ibility of an ac cident 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 : Remov ing even one hand or f oot can reduc e ability to c ontr ol 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 errain 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 mproper tur ns could c ause loss of c ontr ol and lead to 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 at [...]

38 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Climbing hills improper ly . WHA T CAN HAPPEN : I mproper hill climbing 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 ce[...]

39 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : T rav eling downhill improper ly . WHA T CAN HAPPEN : I mproper ly descending 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 re[...]

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 mproper ly cr ossing 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 echniq[...]

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 vehicle c ould overt urn. 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 . When[...]

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 obs tac les could c ause loss of c ontr ol 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 ee[...]

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 : T ir es may f loat, caus ing loss of t ract ion and loss of cont rol, 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 [...]

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 : Use of impr oper t ires, or oper ation of t he A T V wit h improper 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 us e[...]

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 mproper inst allation of acc essor ies or m odific ation 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 ins [...]

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 : Sev ere injury or deat h can res ult 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 i[...]

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 Lamp 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 off 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 Throttle Lever Ele ctroni c Throttle Control This A TV is equipped w ith Polaris Ele ctronic T hrottle Control (ETC) , which 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 sto[...]

54 FEAT URES AND CONTROL S Foot Br ake Y our Polar i s A TV has a f oot peda l (1) that activa t es the rear brak es. It ’ s lo cated in fron t of t he ri gh t-h and footpe g (2) a nd is operate d by t he r i ght foot. If the re ar whe els slide while using the foot brake, r educ e b rake ped al p ress ure t o br ake th e wheel s without skidding[...]

55 FEAT URES AND CONTROL S Br ake L ever The bra ke lever oper ates the front brake s. It’ s loca t ed on the rig ht hand leb ar . Sq ueeze t he brak e lev er to ward t he h andl ebar to engage the f ront br ake s. These br akes are hydr aulica lly acti vat ed d is c ty pe b rakes . Alway s t est brake l ever t ravel and mas ter cy li nder f lui [...]

56 FEAT URES AND CONTROL S Master Cylinder The maste r cylinder (1) is on the right handleb ar . Ch eck t he brak e flu id lev el b efore each ri de. V i ew the fluid leve l through the indicator window (2) on the top of the master cylinde r . This eye wi ll app ear dark whe n the fluid le vel is full. Ad d fluid if the eye is c lear . NOT E: W hen[...]

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 r esult i n an accident and serious injur y or death. Always check to be s ure t he parking brake is disengaged bef ore operat ing. Lo cking th e Parkin g Brake 1. Plac e the tra nsmission in first gear or neutr al. 2. S q ueeze an[...]

58 FEAT URES AND CONTROL S Park in g Bra k e Importa nt Sa fegua rds S The park in g brake m ay relax i f left o n for a long pe riod of time. Alway s block the whee ls to preve nt r olling. S Always block the wheels on t he downhill side of the A TV if le aving it parke d on a hill. Another option i s to par k the A TV in a sidehill position. S Ne[...]

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 exhausted. 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 either leade d or unlea ded gasoline with a minimum pump oc tane number of 87=(R+ M/2) octa ne. Do not use E-85 fuel. Fuel Fil ter The f uel valve ha s an inter nal fuel f ilter . Do not a ttempt to cle an the f uel filter . S ee your[...]

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 upshift to a higher gear , pla[...]

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, place the transmission in ne utral. 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 ga[...]

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. Push the lock-out lever forw ard toward the handleba r to unlock the tra nsmission. 3. Shift down into rev er [...]

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 and 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 l[...]

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 whenev- er handling gasoline. 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 r efue[...]

66 OPERATION Br eak - In Period Car eful tre atment of a ne w e ngine and tr ansmission w ill result in mor e 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[...]

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 101. Add oil i f necessary to maint ain 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 all[...]

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, 139[...]

69 OPERATION Pr e - Ride Insp ection Pre - Ri de Chec kl is t Fram e nuts, bol ts, fast eners Inspect , ensure ti ghtness -- Fuel and oil Ensure proper l evels 101 Coolant l evel (i f applicabl e) Ensure proper l evel 11 2 Coolant hoses (i f appli cable) Inspect f or leaks -- Th ro ttle Ensure proper oper ati on 52, 153 Indi cator l ights / swit ch[...]

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 rea r axle , which dr ives both re ar 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 th[...]

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 level of a lertness, re ading the tr ail and avoiding quic k, shar p turns[...]

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 steep hills (2 5 _ maximum) . 3. Kee p both feet on the footpegs and tra nsfer 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 ak[...]

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 urning 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 urning Around on a Hill 5. Staying uphill of the A TV , turn the handleba rs full left . Reach acro ss t he han dl ebar and app ly t he front br ake s to unlock the park ing bra ke. 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 pa rking on an incline if possible. If it’ s unavoidable, 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 parking bra ke. 4. Always bloc k the re ar whe els on the downhill side. See illustra tion. 5. Shut of f t[...]

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 ca n oper ate through water with 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 ba cking downhill. 2. Bac k slowly . 3. Apply the brakes lightly for stopping. 4. A void turning a t sharp angle s. 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 Control 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 control re quirements ( 40 C FR 205) and loca l noise leve l require ments. Operation on Public Land s in the U.S.A. Y ou r Po lari s veh icl e has a spark arrest or t h[...]

89 EMI SSION CONTROL SYST EMS Cr an kcase Em ission Control System This engine is equipped with a closed c rankca se system. Blow-by ga ses are force d back 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 le ar[...]

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 conditions an d an a vera ge vehic le spee d of approxima tely 10 miles pe r hour . V eh icle s subjected to se vere use must be i nspec ted and servic ed more fre quently . Recor d maintena nce and ser[...]

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 Ke y " 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 for f ree operation and loos e c ompo- nents " Air box sediment tubes -- Pre- Ride -- D rain de[...]

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) Ins pect per iodic ally " Oil C hange 10 H 6M 100 (160) Perfor m brea[...]

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) Drain bow l periodic ally and prior to s tor age J E Thrott le Cable/E TC Switch 50 H 6M 500 (800) Ins pect ; adjust; r eplac e if neces s ary E Chok e (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) I nspec t; t ighten fas teners ; gr ease ( als o after 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) I ns[...]

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) I nspec t s tr ength s easonally ; pr ess ur e 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 annu[...]

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 ex ter nal sur fac e; c hange c oolant ev ery 2 year s " 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 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[...]

101 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 clea n cloth. 4.[...]

102 MAINT ENANCE AND LUBRICATION Engine Oil Level If the A TV is used ye ar -round, c hec k the oil le vel f re quently . A rising oil le vel could 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 lea d to engine dama ge and must be d ra i[...]

103 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e CAUTION If t he A TV is left wit hout oil i n the system for ext ended periods, t he 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 draini[...]

104 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 dra in pan be neath the oil tank a nd re move the [...]

105 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 drain c ompletely . 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 c over bolts [...]

106 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 f acing outwa rd. 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 dipstic k. Fill the oil tank with the re comme nde[...]

107 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 10 8 . Then stop t he engine a nd in sp ect for l eaks . 21. Check the o il level on the dipstick. Add oil as ne cessa ry to bring the le vel to the uppe r mar k on the dipstick. 22. Dispose of the use d filter , oil and shop tow els pr[...]

108 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 engin[...]

109 MAINT ENANCE AND LUBRICATION Air Filter System s 1. Unlatc h and remove the sea t. 2. Loosen the intake duc t 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 t[...]

11 0 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[...]

111 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 ensur e that the coolant mainta ins its a bility to prote ct the engine, we r[...]

11 2 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem Co olant L evel Mainta in the fluid le vel be tween the minimum and maximum marks on the bottle (whe n the fluid is cool). NOT E: T he rec overy bott le (1) may be loc ated on either side of the m achine (depending on your model) under t he fr ont f ender . As co olan t o perat in g t emper[...]

11 3 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 4 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 5 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 6 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 120). 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 ne w lamp. 4. R[...]

11 7 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 [...]

11 8 MAINT ENANCE AND LUBRICATION Lights Head light Ad justmen t 1. Position the A TV on a level surf ace 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[...]

11 9 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[...]

120 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[...]

121 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 plugs[...]

122 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[...]

123 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 1 19-120) . 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 [...]

124 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[...]

125 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[...]

126 MAINT ENANCE AND LUBRICATION Spar k Arr esto r Clean - Out W ARNING Do not per for m clean- out im mediat ely af ter the engine has been run, as t he exhaus t system becomes very hot . Seri ous burns could result f ro m contact 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[...]

127 MAINT ENANCE AND LUBRICATION Spar k Arr esto r Clean - 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 t o cle an the ar re stor scr een ( 3). A synthe tic brush may me lt if component s ar[...]

128 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n If your A TV has be en subme rge d or overtur ned in wa t er deepe r than the f ootpeg le vel, 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 eri[...]

129 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 [...]

130 MAINT ENANCE AND LUBRICATION Batter y The seale d batter y is alre ady fille d with ele ctrolyte and ha s been se aled a nd fully char ged at th e facto ry . N ever pry the se aling strip of f or add any othe r fluid to this batte ry . 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 c[...]

131 MAINT ENANCE AND LUBRICATION Battery Installation 1. Set the ba ttery in the b attery holde r . 2. Conne ct a nd tighten the red ( positive) ca ble first, then c onnect a nd tighten the bla ck (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 properly route d. NOT E: W hen ins[...]

132 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 led and the se aling 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 regist[...]

133 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 Acti on Charge T ime* (Us ing cons tant cur rent char ger @ standard amps spec ified on top of battery) 100% 12.8- 13.0 volt s None, check at 3 mos. f rom dat e of m[...]

134 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 [...]

135 MAINT ENANCE AND LUBRICATION Ti re T r ead Depth Always re place tires when tr ea d depth is wor n to 1/8 ″ (3 mm) or less. Se e illustration. 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 st[...]

136 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[...]

137 MAINTENANCE AND L UBRICATION Wheel Nut T o r que Specification s Ch eck th e wheel n ut t orq ues occas io nal ly an d when t hey ’ve been l oo sen ed for mai nt enan ce servi ce. Bol t Si ze Sp ecif icat io n Fr ont 3/8 ″ 30- 35 ft . lbs. (41-47 Nm ) Rear 3/8 ″ 30- 35 ft . lbs. (41-47 Nm )[...]

138 ADJUST MENTS Br akes Under normal oper ation, the dia phra gm exte nds into the re servoir as fluid le vel drops. If the f luid leve l is low and the diaphrag m is not extende d, a lea k is likely and the dia phragm 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 [...]

139 ADJUST MENTS Br akes 1. Always ke ep brak e fluid a t an ade quate level. See page 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 . Rep lace t he p ads w hen t he fri cti on mat erial i s wo rn to3/64 ″ (1 [...]

140 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 Ali gnment Use the following proce dure to check the toe alignme nt of the vehic le. The Preda tor is [...]

141 ADJUST MENTS T oe Ali gnment 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 front rim (3) . Th[...]

142 ADJUST MENTS Chain T en sion 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[...]

143 ADJUST MENTS Chain T en sion Chec k the amount of c hain sla ck by moving the ve hicle slightly forwa rd to re move sla ck a t 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 suspension with a n adjustab le ( buckl[...]

144 ADJUST MENTS Chain T en sion 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 back to a djust chain sla ck 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 iceli nk Cli p Opening[...]

145 ADJUST MENTS Steer in g Assem b ly The ste er ing assembly of the A TV should be che cked pe riodically f or 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.[...]

146 ADJUST MENTS Suspension Settings Use a fla t blade sc rewdrive r to make d amping 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. Rea r Shoc k (Sta ndard and Li mited E dition) Se ttin g Compr ession Dampi ng Rebound Dampi n g So fte st 20 cli cks fr om clo[...]

147 ADJUST MENTS Fr ont Suspens ion Co mpression D amping ( Limit ed Edit ion) T o adjust the front suspension compr ession damping, use the adjustme nt pr oce dures outlined f or the r ear suspe nsion compre ssion damping on page 151. Spring Prelo a d The f ront suspension pr eload may be adjusted to suit dif fe rent riding c onditions and opera t[...]

148 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 off the ground to a llow the suspension to fu lly exte nd. 2. T urn the a djuster (1) to the left ( A) to incr ease p re load for a stif fer r ide. T urn the adjuste r to the right (B) to decr ease pre load for a softe r ride. NOT E: S ee Susp[...]

149 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 weight. Spring Prelo a d 1. Raise a nd safe ly support t he re ar of the A TV of f the ground to a llow the suspension to fu lly exte nd. 2. Loosen the [...]

150 ADJUST MENTS Rear S uspen sion Rebound Da mping 1. Loca te t he re bound damping clic ker drum betwee n the lower spring seat and the lowe r shock mount. 2. Use a scr ewdrive r make the adjustment. T urn the clic ker counter -c lockwise to decr ease the re bound damping ( A). T urn the clicke r clockw i se to inc rea se re bound damping (B) . N[...]

1 A B 151 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 incr ease compr ession damping, turn the clicker c lockwise (A ). T o dec rease c ompression damping, turn the clicke r counte[...]

152 ADJUST MENTS Clutch Lever F reeplay 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 ″ (3-4. 7 m m). 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 en th[...]

153 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[...]

154 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 [...]

155 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 minutes, or u nt il operat i ng t emp eratu re is reached . 2. Lock the parking br ake. Place the transmission in ne utral. 3[...]

156 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 and/or temper ature 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 operation a nd drivea bility . Above 6000 feet ( 1800 m) the engine a i r/f [...]

157 CLEANING AND ST ORAGE W ash ing th e V eh icle Kee ping your Polaris ve hicle clea n will not only improve its a ppea ranc e but it ca n also exte nd the life of various co mponents. CAUTION High water press ure may damage c omponent s. Polaris recom mends was hing the vehicle by hand or wit h a garden hose, us ing mild soap. Cert ain produc ts[...]

158 CLEANING AND ST ORAGE W ash ing th e V eh icle The be st and sa fest way to c lean your Polar is ve hicle is with a garde n hose and a p ail of mild soap a nd wate r . 1. Use a prof essional-type wa shing c loth, cleaning the upper body first and the lower par ts last. 2. Rinse with c lean wate r fre quently . 3. Dry s urfaces wi th a cham oi s[...]

159 CLEANING AND ST ORAGE W ash ing th e V eh icle If a high pre ssure water syste m is used for cle aning (not re comme nded), exerc ise extre me cauti on. The wat er may d amage components a nd could remove pain t and decal s. A void dire cting the wate r stre am at the following items: S Wheel b earing s S T ransmission se als S Br akes S Cab an[...]

160 CLEANING AND ST ORAGE Polishing the V ehicle Polaris re commends the use of common household ae rosol furniture polish for polishing the finish on your Polaris vehic le. Follow t he instruc tions on the c ontainer . Poli shi ng T ips S A void the use of automotive produc ts, some of which ca n sc ra tch the finish of your ve- hi cle. S Alway s [...]

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 t he engine during t he st orage period. Clean t he Exterio r Make a ny ne cessa [...]

162 CLEANING AND ST ORAGE St or age Recom me ndations Oil and Filt er W arm the engine and cha nge the oil and filter . See page 103. 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 a ir box and dr ain the sedime nt tube. Br eath er Filter Inspe ct and clea n or re place the br eathe r filter [...]

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 r ansporti ng 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 ns[...]

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 See 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 c onnec ti ons Ch eck[...]

167 TROUBLESHOOTING Eng ine T urn s Over , F ails to St art Po ssibl e Cause Sol uti on Out of fuel Tu rn fuel v alve to reserve, refu el Clogge d f ue l va lve In spect an d clean or repl ace W ater is p resen t in fuel Drain t he fuel system an d refu el Fue l va lve i s tur ne d of f T urn the f uel va lve 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 e [...]

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 or n or de fe ct ive s pa rk pl ug 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[...]

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 or co n tam inated fu el Add or c hange f uel , cl ea n the f uel s yst em Lo w octan e fu el Re pla c e wit h re comme nded f uel Ol d, poor or non-r e comme nde d fue l Re pla c e wit h re comme nded f uel Clogge d f ue l [...]

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 repl ace 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 / Special ized Lubri cants 2871312 Gr ease Gun Kit, Pr emium Al l Season ( 3 oz.) Addit ives / Miscel la[...]

174 SPECIF ICATIO NS Pr edator 500 Gro ss V eh icle W e igh 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 Jet N eedle 6CGY07- 060 - 3 Overal l Height 45 in. /1 14 cm Al ternat or Output 200 w @ 3000 R PM Wheel base 50.5 i n./ 128[...]

175 SPECIF ICATIO NS Pr edator 500 Driv ing Sy stem T y pe Rear T wo - Wheel Dri v e T ire Size/Pressure - F ron t 2 1x7 - 1 0/4p s i S hif t T ype 5 - Speed Manual S hift T ir e Size/ Press u re - R ear 2 0x1 1 - 9/4p s i ( S t a n d a r d ) 2 0x1 0-9/ 4p s i( L E ) Driv e Ratio - Fin al 14/ 38 F ront B rake Hydraulic Disc Gear Rat io - 1st 2. 4 R[...]

176 WARRANTY LIM IT ED W ARRANTY Pola ri s Sa le s I nc. , 2100 Highw a y 55, Me dina , MN 55340, give s a SIX MO NTH LIMI TED W ARRANTY on a ll c omponent s of the Pol ar is Al l T er ra in V ehi cl e (A TV) aga ins t def ec ts i n ma te r ia l or wor kma nshi p. Pol ar is a ls o give s a one ye ar l im it e d war ra nty on the f ina l dri ve cha [...]

177 WARRANTY W ARRANTY COVERAGE AND EXCL USIONS: LIMI T A TIONS O F W ARRANTI ES AND REME DIE S 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 ARRANTY COVERAGE AND EXCL USIONS: LIMI T A TIONS O F W ARRANTI ES AND REME DIE S ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED TO THE I MPLIED W ARRANTIES OF MERCHANT ABILI TY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMI TED IN DURA TION T O THE ABOVE SIX MONTH W ARRANTY P ERI OD. POLARI S FUR THER DISCLAI MS ALL EXPRESS [...]

179 WARRANTY HOW TO OBT AIN W ARRANTY SERVICE I f your A TV r equi re s wa rr ant y se rvi ce , you m us t t ake i t 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 R egi st ra ti on f orm to t he 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 TI ON. Th is po licy d o es n o t app ly to v ehicles th at h av e receiv ed au th o rization fo r e xpor t fr om Pola ri[...]

181 WARRANTY Exported V ehicles How to G et S erv ic e In th e C o un try w h ere you r veh icle w as p u rch a sed: W a rr ant y or Se rvi ce Bull et in r epa ir s m ust be done by an a uthor iz ed Pol ar is 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 a rr ant y or Se rvi ce Bull et [...]

182 WARRANTY Exported V ehicles How to G et S erv ic e If P urch a sed Fro m A P rivate P a rty: I f you pur c ha se a Pol ar is pr oduct f r om a pri vat e ci ti ze n outs ide of t he count ry in whic h the ve hic le wa s ori gina ll y pur c has ed, a ll wa rr ant y cove ra ge wil l be deni ed. 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 i on s L i mit e d W a rran t y Th is All T errain V ehicle (A T V) or Off R oad U tility V ehicle (ORU V ) em ission s limited warran ty is in add itio n to th e P o laris stan d ard limited w arran ty for this veh icle. Po laris w arran ts th at this v eh icle is; (1 ) d esig ned , b u ilt, an d eq u ip ped to co [...]

184 WARRANTY U. S.A. EP A Emi ss i on s L i mit e d W a rran t y Th e ex clu sive rem ed y fo r b reach of th is limited warran ty sh all be, at th e ex clu sive o p tio n o f P o laris, rep air or re- p lacemen t o f an y defectiv e m aterials, com ponent s or produc ts . THE REMEDI ES SET FOR TH IN TH IS LIM - ITED W ARRANTY ARE THE ONL Y REMEDI [...]

185 MAINT ENANCE LOG 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.[...]

186 MAINT ENANCE LOG Mai ntenance Int erval Perf orm ed Se rv icin g Date Se rv icin g Dealer or Person Remarks[...]

187 INDEX A Age Restrictio ns 14 ................ Air Filter System s 109-1 10 ........... B Battery 1 30 ...................... B at tery C har ging 132-133 ............ Battery I nstallatio n 13 1 ............. B at tery R emoval 130 ............... B at tery S torage 131 ................ Brak e Fluid 5 6 .................... Brake Lever s 5 5 ..[...]

188 INDEX L Light S wit ches 51 ................. Light s 50, 1 14-118 ................. Lubri cati on Rec ommendat ions 100 .... M Mai ntena nce 90-137 ................ Mai ntena nce Log 185-186 ........... Maki ng Tur ns 75 .................. Manua l Shift 61-64 ................. Mas ter C yli nder 56 ................ N Noise Em ission Co ntro l [...]