Polaris 450 MXR manual

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A card containing importan t A TV safety information sh ould be attached to the owner's manual on the next page. If you cann ot locate this card, or if it has been removed, please ca ll 1-800-342-3764 for assista nce. W ARNING The engine exhaust from this product contains chemicals known to the State of Ca lifornia to cause cancer , birth defe[...]

1 Visit us at www .polarisindustries.com[...]

2 POLARIS and POLARIS TH E W A Y OUT are register ed t rademarks of Polari s Industries Inc. Copyright 2008 Polaris Sales Inc. All in formation contained within this publication is based on the latest p roduct information at the time of publicat ion. Due to constant improvements in th e design and quality of production components, some minor discre[...]

3 We lc o m e Thank you for purchasin g a Polaris vehicle, and welcome to our world-wide family of Polaris owners. W e proudly produce an exciti ng line of utility and recreational products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER utility vehicles • V ictory motorcycles[...]

4 Wel c o m e W e believe Polaris sets a standard of excellen ce for all utility and re creational vehicles man- ufactured in the worl d today . Many years of experience have gone into the engineering, design, and developmen t of your Polaris vehicl e, making it the finest machine we 've ever produced. For safe and enjoyab le operation of your[...]

5 T able of Content s Introduction . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . 10 F eatures and Controls . . . . . . . . 38 Operation . . . . . . . . . . . . . . . . . . 58 Emission Control S ystems . . . . . 85 Maintenance . . . . . . . . . . . . . . . . 87 Specifications . . . . . . . . . . . . . . 168 P[...]

6 Introduction Safety Wo rds and Symbols The following signal words and symbols appear throu ghout this manual an d on your vehicle. Y our safety is involve d when these words and symbols are used. Become familiar with their meanings before r eading the manual. The safety alert symb ol indicates a potential personal injury hazard. W ARNING A W ARNI[...]

7 Introduction Failure to follow the warnings and safe ty precautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be hazardous to opera te. This vehicle handles differently than other vehicles, su ch as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuv[...]

8 Introduction V ehicle Identification Numbers Record your vehicle's identification number s and key number in the spaces provided. Remove the spare key and store it in a safe place . An ignition key can be duplicated only by ordering a Polaris key blank (using your ke y number) and mating it with one of yo ur existing keys. The ignition switc[...]

9 Introduction V ehicle Identification Numbers V ehicle Model Number: __ _____________________________________________________ _________________ F rame V ehicle Identifica tion Number (1): ___________________________________________________ _______ Engine Serial Number (2): ________________________________ ______________________________________ Key[...]

10 Safety Safety T raining A TV safety training is a top priority for Polaris. When you purchased yo ur new A TV , your dealer instructed you on the authorized A TV RiderCourse sm available to you and your eligible family members. This training is included in the purchase price of your A TV . Polaris strongly encourages you and your age eligib le f[...]

11 Safety Safety T raining A Polaris A TV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Follow the recommen ded maintenance program outlined in yo ur owner's manual. This program is designed to ensure that all critical components on your vehicle are thoroughly [...]

12 Safety Equipment Modifications W e are concerned for the safety of our custom ers and for the general public. Therefore, we strongly recommend that consumers do not in st all on a Polaris A TV any equipment that may increase the speed or pow er of the vehicle, or make a ny other modifications to the vehicle for these purposes. Any modifications [...]

13 Safety Safe Riding Gear Always wear clothing suited to the type o f riding. A TV riding requires special protec tive clothing for comfort and to reduce the ch ance of injury . Helmet W earing a helmet can prevent a severe head injury . When- ever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safe ty standards. [...]

14 Safety Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses fo r eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet fac e shield. Polaris recommends wearing approved Personal Protec tive Equipment (PPE) bearing markings such as VESC 8, V -8, Z87.1, or CE. Make su [...]

15 Safety Safety W arnings Failure to operate the A TV properly ca n result in a co llisi on, loss of control, a ccide nt or overturn, which may result in serious injury or death. Heed all safe ty warnings outlined in this section of the owner ’s manual. See the OPERA TION section of the ow ner ’s manual for proper operating proc edures. Operat[...]

16 Safety Safety W arnings Operating Without Instr uction Operating this A TV without proper in struction increases the risk of an accident. The operato r must unde rstand how to operate the A TV properly in different situations and on different types of terrain. Beginning and inexperienced oper ators should comp lete the A TV RiderCourse sm offere[...]

17 Safety Safety W arnings Handling Gaso line Gasoline is highl y flammable and explosive under certain conditio ns. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refueling[...]

18 Safety Safety W arnings Failure to Inspect Be fore Operating Failure to inspect and verify that the A TV is in safe operating condition before operating increases the risk of an accident. Always inspec t the A TV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedu res and sched[...]

19 Safety Safety W arnings Carrying a Passenger Carrying a passenger greatly reduces the operator's ability to balance and con trol the A TV , which may result in an accident or overturn. Never carry a passenger on this A TV . Using Alcohol or Drugs Operating the A TV after consuming alcohol or drugs could adverse ly affect operator judgment, [...]

20 Safety Safety W arnings Operating on Pavement Operating an A TV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the A TV and could result in loss of control and accident or overturn. Avoid operating the A TV on pavement. A TV tires are de signed for of f-road use. If it's unavo[...]

21 Safety Safety W arnings Operating at Excessive S peeds Operating the A TV at excessive speeds increases the operator's risk of l osing control. Always operate at a speed that's appro priate for the terrain, the visibility and operating cond itions, and your experi ence. Physical Control of the A TV Removing a hand from the handleb ars [...]

22 Safety Safety W arnings T urning Improperly T urning improperly could cau se loss of traction, loss of control, accident or overturn. Always follow proper proced ures for turning as de scribed in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn a[...]

23 Safety Safety W arnings Improper Hill Climbing Improper hill climbing c ould cause loss of control or overturn. Always follow proper p rocedures for climbing hills as described in the owner's manual. See page 72. Operating on S teep Hills Operating on excessively ste ep hills could cause an overturn. Never operate on hills too steep for the[...]

24 Safety Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures for traveling down hill s as described in the owner's manual. NOTE: A special tech- nique is required when braking while travelin g downhill. See page 78. • Always descend a hill wit[...]

25 Safety Safety W arnings Crossing Hillsides Driving on a sidehill is not recommended. Improper p rocedure could cause loss of control or overturn . Avoid crossing the side of any hill unless absolutely necessary . If crossing a hillside is unavoidabl e, always follow proper procedures as described in the owner's ma nual. See page 74. Never a[...]

26 Safety Safety W arnings St alling While Climbing a Hill S talling, rolling backwards or improp erly dismounting while climbing a hill could cause a n overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost Keep body weight uphill. Apply the front brakes gradually (right lever). When fully sto pped, apply th e [...]

27 Safety Safety W arnings Operating on Slippery T errain Failure to use extra caution when operati ng on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loo se terrain until you've learned and practiced the skills necessary to co[...]

28 Safety Safety W arnings Operating in Unfamiliar T errain Failure to use extra caution when operati ng on unfamiliar terrain could result in an accident or overturn. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn. T ravel slowly and use extra caution when operating on unfamiliar te rrain.[...]

29 Safety Safety W arnings Improper V ehicle Modifications Improper installation of accessories or modification of the A TV may cause changes in handling, which could caus e l oss of control or an accident. Never modify the A TV through improper installation or use of accessories. All parts and accessories added to the vehicle must be genuine Polar[...]

30 Safety Safety W arnings Operating Through Deep W ater Operating the A TV through deep or fast-flowing water cou ld cause the tires to float, causing loss of control or overturn. Avoid operating through de ep or fa st-flowi ng water . If it' s unavoidable to enter water that exceeds the height of the footpegs: • T ravel slowly . • Balanc[...]

31 Safety Safety W arnings Poor Visibility Operating the A TV in darkness or inclement weather coul d result in a collision or accid ent, especially if operating on a road or street. This A TV is not e quipped with highway-approved lights. Operate this vehicle off-road only . Use caution a nd drive at reduced speeds in conditions of reduced visibil[...]

32 Safety Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bod ies of water may result in serious injury or death if the A TV and/or the operator fall through the ice. Never operate the A TV on a frozen body of water . Operating a Damaged A TV Operating a dama ged A TV can result in an accident. After any overturn or accide[...]

33 Safety Safety W arnings Hot Exhaust Sys tems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the e xhaust system. Use caution when traveling through tall grass, especially dry grass. Unautho[...]

34 Safety Safety Labels and Locations W arning labels have been placed on the vehicle for your protectio n. Read and follow the instructions on each label carefully . If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic [...]

35 Safety Safety Labels and Locations General W arning W ARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gear . Never use on public road s. Never carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instructio n • at speeds too fast for yo ur [...]

36 Safety Safety Labels and Locations Age 16 W arning W ARNING Operating this A TV if yo u are under the age of 16 increases your chance of severe injury or death. NEVER operate this A TV if you are under age 16. 7175374 Discretionary/Sport A TV Wa rning W ARNING • Never operate this A TV on HILLS steeper than 25 degrees 25 ° . T o preve nt over[...]

37 Safety Safety Labels and Locations No Passenger W arning W ARNING NEVER ride as a passenger . Passengers can cause a loss of control, resulting in SEVERE INJURY or DEA TH. 7175378 Tire Pressure/Load W arning W ARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold ti[...]

38 Features and Controls Start Butto n Engine Stop Switch Main Key Switch[...]

39 Features and Contro ls Main Key Switch The main key switch must be in the RUN position to start the engine. See page 66 for starting procedures. Star t B u t to n Press the start button to engage the starter . Alwa ys release the start button promptly w hen the engine starts. If the starter fails to engage, re place the blown fuse or see your Po[...]

40 Features and Controls Light s Indicator Light s An illuminated light in the indicator window will alert you to the follow- ing conditions. • Hot engin e • Reverse gear is selected • Neutral gear is selected If indicator lights fail to operate, check connections. See your Polaris dealer for inspection of the capacitor and voltage regulator [...]

41 Features and Contro ls Light s Headlight s Use the headlight switch to turn the li ghts on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Headlight Switch[...]

42 Features and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar . Squeeze the clutch lever toward the handlebar to disengage the clutch. Disengage the clutch before shifting gears. The clutch is self-adjusting, but lever position can be changed to fit the operator’ s hand. T urn the adjusting knob counterclockwis[...]

43 Features and Contro ls Clutch Fluid The clutch fluid master cylinder is located on the left handlebar . Check the fluid level in the reservoir before each ride. The level should be 4mm below the upper edge of the re servoir . Do not overfill. Polaris recommends the use of KTM Hydraulic Clutch Oil. Do not use brake fluid. Do not mix clutch fluid [...]

44 Features and Controls Throttle Lever Operating an A TV with sticking or improperly operating throttle co ntrols could cause an accident. Never start or operate an A TV that has a sticking or impr operly operating thro ttle. Always contact your dealer for service before operating the ve hicle. Failure to check or maintain proper operation of th e[...]

45 Features and Contro ls Throttle Lever The throttle lever is located on the right handlebar . Squeeze the lever toward the handlebar to increase engine s peed and vehicle moveme nt. Fuel is injected into the inta ke passage each time throttle is app lied. Do not squeeze the throt- tle lever while starting the engine. Do not squeeze the throttle l[...]

46 Features and Controls Foot Brake The foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. If the rear wh eels slide while using the foot brake, reduce brake pedal pressure to brake the wheels without skidding. Check the brake fluid le vel frequently for the foot brake system. The reservoir is locate[...]

47 Features and Contro ls Hand Brake The hand brake operates the front brakes. The hand brake is located on th e right handlebar . These brakes are hydrau lically activated disc type brak es. Squeeze the brake lever toward the hand lebar to engage the front brakes. Always test brake lever travel and master cylinder fluid level before riding. When s[...]

48 Features and Controls Master Cylinder/Brake Fluid An over-full master cylinder may cause brake drag or brake lock-up, which could resul t in an accident. Maintain brake fluid at the reco mmended level. Do not overfill. Never store or use a partial bottle of brake fluid. Br ake fluid is hygroscopic, meaning it rapidly absorbs moisture from the ai[...]

49 Features and Contro ls Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder be fore each ride. If the fluid level is low add DOT 4 brake fluid only . Do not overfill. See pa ge 172 for the part nu mbers of Polaris prod- ucts. Hand Brake Fluid Level 1. Position the A TV on a level surface. Position the handlebars so the mast e[...]

50 Features and Controls Parking Brake 1. Place the transmission in first gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking b rake lock do wn to engage the lock. Release the brake lever . 4. T o release the pa rking brake lock, squeeze and release the brake lever . The lock will automatical[...]

51 Features and Contro ls Parking Brake The parking brake may relax if left on for a long period of time. Always b lock the wheels to prevent rolling. Always block th e wheels on the downhill side of the A TV if leaving it parked on a hill. Another option is to par k the A TV in a sidehill position. Never depend on the park- ing brake alone if the [...]

52 Features and Controls Manual Shif t Shif t Pedal The gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts the tr ansmission to the next gear in the shifting sequence. The pedal automa tically returns to a horizontal position when released. T o upshift to a higher gear , place the toe of your b oot un[...]

53 Features and Contro ls Manual Shif t Shif ting Gears Always allow a cold engine to warm up before shifting gears. 1. When starting from a stopped pos ition, place the transmission in neutral. 2. Squeeze and hold the brake lever . Do not apply throttle. 3. Squeeze the clutch lever to disengage the clutch. 4. Depress the gear shift pedal one full [...]

54 Features and Controls Manual Shif t Reverse Lock-Out Switch The reverse lock-out switch prevents the operator from shifting into reverse uninten- tionally . The switch must be manually unlocked before shifting into reverse gear . The lock will automatic ally re-eng age when the transmission is shifted out of reverse gear . 1. Place the transmiss[...]

55 Features and Contro ls Manual Shif t Deceleration T o slow or stop the vehicle , release the thro ttle lever and apply the brakes smoothly and evenly . As the vehicle slows and engine speed decreases, disengage the clutch and shift to a lower gear . Be sure engine speed ha s sufficiently decreased before downshifting. W ARNING! Improper use of t[...]

56 Features and Controls Choke The choke assists in starting a cold engine. The choke knob is located on the left side of the carburetor . Refer to the engine starting procedure on page 66 for correct choke and throttle settings during starting. Fuel T ank The fuel tank filler cap is located directly below the handlebar . Polaris recommends the use[...]

57 Features and Contro ls Fuel V alve The fuel valve is located on the right side of the A TV . It has three positions: OFF: For vehicle storage and when transporting. T u rn the fuel valve off whenever the vehicle is stored or parked. ON: For normal operation. RES: For reserve supply if main supply is exhausted. There's about a 5 to 8 mile (8[...]

58 Operation Failure to operate the A TV properly ca n result in a co llisi on, loss of control, a ccide nt or overturn, which may result in serious injury or death. Read and unde rstand all safet y warnings ou tlined in the safety section of this owner ’s manual. Break-In Period The break-in period for your new Polaris A TV is the first three ho[...]

59 Operation Break-In Period Perform the following break-in and maintenance procedures carefully . 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever han- dling gasoline. 2. Check the oil level. Add the recom- mended oil as needed to maintain the oil level in the proper range. See page 99. 3. Allow the engine suf ficient [...]

60 Operation Pre-Ride Inspection Failure to inspect and verify that the A TV is in safe operat ing co ndition before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Pre-Ride Checklis t P age Brake systems / lever travel En sure proper operation 46-51 142-143 Br[...]

61 Operation Pre-Ride Inspection Pre-Ride Checklis t P age Coolant (if applicable) Ensure proper level 109 Coolant hoses (if applica ble) Inspect for leaks -- Throttle Ensure smooth operation 44 Indicator lights / switches Ensure operation 40, 41 Engine stop switch Ensure proper operati on 39 Air filter Inspect, clean, re place as needed 112 Air bo[...]

62 Operation Safe Operation Practices 1. Complete the re commended safety training before operating this vehicle. See page 10. 2. Do not allow anyone un der 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical dis- abilities to operate this vehicle. 3. Never carry a passenger on this A TV . 4. Engine exhaust f ume[...]

63 Operation Safe Operation Practices 8. Drive in a manner ap propriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the h an- dlebars while op erating, and always keep both feet on the footpegs. 9. Never consume alcoho l or drugs before or [...]

64 Operation Know Y our Riding Area/T read Lightly Familiarize yourself with all laws and regulatio ns concerning the oper ation of this off-road vehicle in your area. Respect the environment in which you ride. Find o ut where the desig- nated riding areas are by contacting your Polaris dealer, a local riding club or local of ficials . Help keep ou[...]

65 Operation T rail Etiquette Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Comm unicate to oncoming opera tors by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of th e trail as far as possible to allow others to pa[...]

66 Operation St arting the Engine The engine ca n be started when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting a warm engine, do not use the choke. Fuel is injected into the inta ke passage each time the thro ttle lever is depressed. Do not depress the throttle lever while starting the engine . Do not de[...]

67 Operation St arting the Engine 5. Move the engine stop switch to the RU N posit ion. T urn the ignition key to ON. 6. If starting the engine while in gear , apply the hand brake and squeeze the clutch lever fully to disengage the clutch. If starting the e ngine while in neutral, the neutral indicator light should be on. If it isn't, disenga[...]

68 Operation Driving Procedures 1. W ear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on the h andlebars. 3. Star t the engine and allow it to warm up. 4. Shift the transmission into gear . See page 52. 5. Check your surroun dings and determine your path of travel. 6. Release the parking brake. 7. Slowly[...]

69 Operation Making T urns Y our A TV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of the turn travels a greater distance th an the inside wheel when turn- ing, and the inside tire slips traction slightly . T o turn, steer in the direction of the turn, leaning your upper body to th[...]

70 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Do not operate on excessively rough, slip- pery or loose terrain. 2. Slow down when entering slippery areas. 3. Maintain a high level of alertness, reading the trail and avoidin[...]

71 Operation Driving on Slippery Surfaces 4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting yo ur body weight fo rward. Sideways skid Tu r n i n direction of skid[...]

72 Operation Driving Uphill Braking and handling are greatly af fected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. When- ever traveling uphill, fo llow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrain carefully before ascending any hill. [...]

73 Operation Driving Uphill 5. Keep both feet on the footpegs . 6. Shift body weight uphill. 7. Proceed at a steady rate of speed and thro ttle opening. Opening the throttle suddenly could cause the A TV to flip over backwards. 8. Never back down a h ill. W ARNING! Aggressively appl ying the foot brake when b acking down a hill may cause rear tipov[...]

74 Operation Driving on a Sidehi ll (Sidehilling) Driving on a sidehill is not recommended. Im proper procedur e could cause loss of c ontrol or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper b[...]

75 Operation T urning Around on a Hill If the vehicle stalls while climbing a hill, never back it down the hill! Us e the K-turn to turn around: 1. Keep your body weight uphill. 2. Pull in the clutch lever and apply the front and rear brakes. 3. When completely stopped, sh ut of f the engi ne. Leaving the transmission in gear , release the clutch l[...]

76 Operation T urning Around on a Hill 7. W ith the front bra kes applied, pull in the clutch lever . Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly down- ward. 8. W ith the front bra kes still applied, release the clutch lever and lo ck the parking brake. Remount from th[...]

77 Operation T urning Around on a Hill 9. Pull in the clutch lever , shift in to neutral and restart the engine. 10. Release the parking brake and slowly release the clutch lever , allowing the A TV to pro- ceed slowly . Stay in first gear , using the brakes for additional speed control if necessary , until more level gr ound is reached. 1 1. Follo[...]

78 Operation Driving Downhill When driving downhill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uphill. Transfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when traveling downhill can cause loss of control. 5. Shift to the lowest ge ar possible while m[...]

79 Operation Parking on a Hill or Incline A void parking on an in cline if possible. If it's unavoidable, follow these precau- tions: 1. S top the engine. 2. Place the transmission in first gear . 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side. See illustration. 5. T u rn the fuel valve off.[...]

80 Operation Driving Through W ater Polaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions when operating through wat er: 1. Determine water depth and current before entering water . 2. Choose a crossing where the water level is lowest and where both banks have grad ual inclines. 3. A void ope[...]

81 Operation Driving Through W ater NOTICE: Serious engine damage can result if the vehicl e is not thoroughly i nspected after operating in water deeper than the footpeg level. As s oon a s possible, perform th e inspections and maintenance services outli ned in the period ic maintenance chart be ginning on page 87. Engine oil and all grease fitti[...]

82 Operation Driving in Reverse Follow these precautions w hen operat- ing in reverse: 1. Always check for obstacles or peo- ple behind the vehicle. 2. Always avoid backing downhill. 3. Back slowly . 4. Apply the bra kes lightly for stop- ping. 5. A void turning at sharp ang les. 6. Never open the throttle suddenly while back ing.[...]

83 Operation Driving in Reverse 7. Do not operate at full throttle. Use just enough throttle to main tain a desired speed. 8. Always look left, right and behin d the A TV before backing . NOTICE: Excessive throttle o peration while in the sp eed limi t mode may cause fuel to build in the exhaust, resulting in engine popping and/or eng ine damage.[...]

84 Operation Driving Over Obst acles Follow these precautions whe n operating over obstacles: 1. Always check for obstacles before oper- ating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches. 3. T ra vel slowly and use extra caution when operating on unfamiliar[...]

85 Emission Control Systems Noise Emission Control System Do not modify the engine, intake or ex haust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level requ ire- ments. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spa rk arrestor that was tested and q[...]

86 Emission Control Systems Exhaust Emission Control System The emissions from the exhaust of this vehicl e are controlled by engine design, including factory-set fuel delivery and ignition. The en gine and related compon ents must be main- tained at Polaris specifications to achieve optimal performance. Engine idle speed is the only adjustment Pol[...]

87 Maintenanc e Periodic Maintenance Chart Routine inspection and service are critical to the performance and rel iability of your high performance engine. Failure to perform the recommended maintenanc e procedures outlined in the Periodic Maintenance Chart will resu lt in forfeited warranty coverage as well as decreased performan ce and reliabilit[...]

88 Maintenance Periodic Maintenance Chart The recommended se rvice intervals are based on aver age riding conditions. V ehicles sub- jected to severe use must be inspected and serviced more frequently . Severe Use Definition • Frequent immersion in mud, water or sand • Racing or race-style hig h RPM use • Prolonged low speed, heavy load opera[...]

89 Maintenanc e Periodic Maintenance Chart Improperly performing the pr ocedures marked wi th a Q could re sult in component failure and cause an accident, which may result in serious inju ry or death. Always have an authorized Polaris dealer perfo rm these services. Maintenance Chart Key X Perform these operations mo re often under severe use. E E[...]

90 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used Brake systems/brake fluid -- Pre-ride -- Check each day before operating the vehicle. Make adjustments as needed. See the Pre-Ride Checklist. 60 Tires - - -- Wheels/lug nuts -- -- Fr ame fasteners -- -- Coolant --[...]

91 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

92 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons (liters) Brake pad wear 10 Monthly -- Inspect regularly 143 Battery 10 Monthly -- Check terminals; clean; test 129 X E Air filter 15 Weekly -- Inspect; clean; replace as needed 112 X Oil and filter chan[...]

93 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

94 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) X z Upper steering post (1) 45 6 M -- Inspect; tighten fasteners; grease after washing A TV/driving in wate r X z F ront A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease (also after washing A TV o[...]

95 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

96 Maintenance Periodic Maintenance Chart Item Maintenance In terval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) E Compression ring 90 -- 156 (600) See your dealer or refer to the Dealer Service Manual; measure ring gap and replace if at or below service limit E Oil scraper ring 90 -- 156 (600) Camshaft 90 -- 156 ([...]

97 Maintenanc e Periodic Maintenance Chart X Perform these procedures more often fo r vehicles subjected to severe use E Emission-Related Service Q Have an authorized Polaris dealer perform these services z Use Polaris Premium All Season Grease Item Maintenance In terval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons[...]

98 Maintenance Engine Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Periodi c Maintenance Chart beginning on page 87. Po laris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a similar oil desi gned for use in 4-stroke manual clutch A TV and motorcycle app lications[...]

99 Maintenanc e Engine Oil Level Check the oil level before each use of the vehi- cle. If the engine is cold , the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible between the 1/2 and 3/4 levels in the sight glass. 1. Position the vehicle on a level surface. 2. V iew the oil le[...]

100 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. Change the oil mo re frequen tly on vehicles subjected to severe use. IMPORT ANT : Perfo rm the initial break-i n oil change afte r the first three hours of operation. Always change both oil filters and clean t h[...]

101 Maintenanc e Engine Oil Change 1. Position the vehicle on a level surface. 2. Star t the engine. Allow it to idle for two to three minutes. S top the en gine. 3. Place a drain pan beneath the crankcase. Remo ve the drain plug. Allow the oil to drain completely . CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 4. [...]

102 Maintenance Engine Oil Change Cleaning the Short Oil Screen Short Screen Short Oil Screen Plug View from bottom of vehicle Fr o n t O-Rings[...]

103 Maintenanc e Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen pl ug at the bottom of the engine. 2. Remove the short oil screen. Clean the sc reen components thor oughly and blow well with low pressure compressed air . 3. Check the O-rings. If damaged, install new O-rings. 4. Reinstall the screen to the plug. 5. Lu[...]

104 Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen plug , located on the side of the engine near the engine number . 2. Remove the oil screen. Clean the screen thoroughly and blow with compressed air . 3. Check the O-rings. If damaged, install new O-rings. 4. Place the long oil screen on a pin-type key or simil[...]

105 Maintenanc e Engine Oil Change Cleaning the Long Oil Screen 5. Insert the tool through th e op ening and into the bore of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. NOTICE: An improperly installed oil screen will function poorly and result in increased engine wear . Install the scre[...]

106 Maintenance Engine Oil Change Changing Oil Filters 1. Place a drain pan under the engine. 2. Remove the four oil filter cover screws (1). Remove the co vers. 3. Using circle clip (sna p ring) pliers, pull the oil filter inserts (2) out of the housing. 4. Thoroughly clean the engine casing, filter covers and sealing surfaces of the O-rings. Chec[...]

107 Maintenanc e Engine Oil Change Changing Oil Filters 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. T ighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fi ll plug (4). Add 40 oz. (1.2 liters) of the recommended engine oil (see page 98). Reinstall the fill plug. 9. Star t the engine. Allow it to idle for at [...]

108 Maintenance Engine Cooling System The engine coolant level is cont rolled or maintained by the recovery system. The recovery system components are the recovery bottle, radiator filler neck , radiator pressure cap and connecting hose. T o ensure that the coolant maintains its ability to protect the engine, we recommend that you completely drain [...]

109 Maintenanc e Engine Cooling System Coolant Level The recove ry bottle is loca ted on the right side of the vehicle under the front fender . If the fluid level is vis- ible at the bottom of the side panel, add 6 oz. (175 ml) of coolant. As coolant operating te mperature increases, the expanding (heated) excess coolant is forced out of the radiat[...]

110 Maintenance Engine Cooling System Radiator Coolant Level If the recovery bottle has run dry , inspect the level in the radiator and add coolant if necessary . The radiator pressure cap is located on the left side of the vehic le. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow[...]

111 Maintenanc e Engine Cooling System Cooling System Bleeding Bleeding the cooling system is required only if the syst em has been drained for maintenance and/or repair . Always allow the engine to cool sufficiently before removing the radiator pres- sure cap. 1. Remove the pre ssure cap. 2. Using a funnel, slowly add th e recommended coolant. Fil[...]

112 Maintenance Air Filter Systems 1. Remove the seat. 2. Release the airbox cover clips and remove the cover . 3. Remove the wing nuts securi ng the filter to the airbox. 4. Pull the filter assembly out of the air box. Note the placement of th e rubber ring for rein- stallation. 5. W ash the filter in soapy water , then rinse and let dry . 6. Appl[...]

113 Maintenanc e Carburetor Normal wear from engine vib rations may cause th e carburetor to supply an overly rich fuel mixture. Replace the jet needle and the need le jet after every 180 hours of operation. Idle S peed Carburetor idle adjustments affect engine star t ing behavior . A proper idle sp eed of 1700- 1800 RPM will result in easier start[...]

114 Maintenance Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be ginni ng on page 87. Al ways drain the bowl after exposure to wet conditions. Perform this procedure when the engin e is cool. 1. T u rn the fuel valve off. 2. Place a suitable container under the carburetor [...]

115 Maintenanc e Carburetor Jetting Carburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be operated at various altitudes an d temperatures, certain adjust- ments can be made to improve its operation and driveability . Ab ove 6000 feet (1800 m) the engine air/fuel mixture becomes overly [...]

116 Maintenance Light s Headlight Adjustment 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall. 2. Measure the distance from the floor to the center of the h eadlight and make a mark on the wall at the same height. 3. Star t the engine and turn the headlight switch to high beam. 2 " (5 [...]

117 Maintenanc e Light s Headlight Adjustment 4. Observe the headlight aim on the wall. The most intense part of the headlig ht beam should be aimed 2" (5 cm) below the mark placed on the wall. Include rider weight on the seat when measuring. 5. Loosen the pivot screw an d adjust the beam to the desired position. 6. T ighten the screw and torq[...]

118 Maintenance Light s Headlight Lamp Replacement When servicing a halogen lamp, av oid touching the lamp with bare fingers. Oil from your skin leaves a residue, cau sing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. 1. Remove the wire harness connecto r from the back of the headlig[...]

119 Maintenanc e Light s Headlight Assembly Replacement 1. Remove the fron t cover . 2. Remove the wire harness connector from the headlight. 3. Remove the two retaining brac kets and the adjuster screw . 4. Remove the head lamp. 5. Install the new headlamp, placing it in the sl o ts on the f rame tabs. Sec ure the headla mp with the retaining brac[...]

120 Maintenance Front Cab/Side Panel Removal The front cab and side panel assembly is removed in one piece. 1. Remove the seat. 2. Remove the two fro nt cover screws and remove the front cover . 3. Remove the eight side panel screws (four on each side). 4. Remove the fuel cap. 5. Gently pull the side panel/cab assembly upward and rearward. 6. Unplu[...]

121 Maintenanc e Rear Cab Removal 1. Remove the seat. 2. Remove the two lower bolts (1) on the rear fenders of the cab. 3. Remove the two bolts and grommets (2) on the top of the cab. 4. Remove the two bolts (3) at the rear cab-to-front-cab joint. 5. Unplug the taillight connector . 6. Remove th e cab. 1 3 2[...]

122 Maintenance Sp ark Plugs Refer to the specifications section beginnin g on page 168 for recommended spark plu g type and gap. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommende d spark plugs. Spark plug condition is indicative of engine operation. The spark plug firing end conditi on sho[...]

123 Maintenanc e Sp ark Plugs Normal Plug The normal insulator tip is gray , tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. The tip should not be white. A white insulator tip indicates overh eating, caused by use of an [...]

124 Maintenance Sp ark Arrestor Clean-Out Failure to heed the following warnings w hile servicing the spark arrestor could result in serious injury or death. The exhau st system can get extremely hot. Do not perform service on the sp ark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. Remove any combustibl[...]

125 Maintenanc e Sp ark Arrestor Clean-Out T o remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Mai ntenance Chart beginning on page 87. 1. Remove the retaining screw and remove the arrestor from the end of the muf fler . 2. Use a non-syn thetic brush to clean the arrestor screen. A synthetic brush ma[...]

126 Maintenance V ehicle Immersion If the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stop s during or after operating in water , restartin g WILL result in serious engin e damage. T rans- port the vehicle to your dealer for service befo re restarting the engine. If this is not possible, follow the vehicle imm[...]

127 Maintenanc e V ehicle Immersion 1. T u rn the fuel valve off. 2. Drain water from the air box and cl ean the air filter . See page 1 12. 3. Drain the carburetor bowl . See page 1 14. 4. Remove the sp ark plug. See page 122. W ARNING! Fluids will be eje cted through the spark plug hole and may cause serious injury to face or other body part s. W[...]

128 Maintenance V ehicle Immersion 6. Press and hold the starter button for 10 sec ond intervals for about one minute or until water vapor is no longer ejec ting from the spark plug hole. 7. Check the oil level. If the level is higher than the pre-ride insp ection level, water has entered the crankcase. Do not start the engine. T ransport the vehic[...]

129 Maintenanc e Battery Improperly connecting or disconnec ting battery cables can result in an expl osion and cause serious injury or death. When removing the battery , always disconne ct the negative (black) ca ble first. When reinstalling the battery , always connect the negati ve (black) cable last. The sealed b attery is alread y filled with [...]

130 Maintenance Battery S torage Whenever the vehicle is not used for a period of three months or more, remov e the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. Battery Removal 1. Remo[...]

131 Maintenanc e Battery Inst allation Always install a fully charged battery . Using a new battery that has not been fully charged can damage the battery and result in a shorter lif e. It can also hinder vehicle performance. If recharging is necessary , use a .5 amp ba ttery charger . 1. Place the battery in the batter y holder . 2. Connect and ti[...]

132 Maintenance Battery Charging (Sealed Battery) On a sealed battery , the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC voltage. A fully char ged battery will register 12.8 V or h igher . If the voltage is less than 12.8 volts, recharge the battery . W ARNING! An overheated battery could explode , causin g severe in[...]

133 Maintenanc e Battery Charging (Sealed Battery) The Polaris Battery T ender batte ry char ger can be left connected during the storage period and will automatically char ge the battery if th e voltage drops below a pre-determined point. If the battery fails to recharge during vehicle operation, check voltage regulator connections. See your Polar[...]

134 Maintenance Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. State of Charge V oltage Action Charge Time (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 vo lts None, check at 3 mon ths from date of manufacture None required 75%-100% 12.5[...]

135 Maintenanc e Ti r es Operating your A TV with worn tires, imprope rly inflat ed tires, non-standard tires or improperly installed tires will affect vehicle handling and could ca use an accident resulting in serious injury or death. Al ways follow all ti re maintenance proced ures as outlined in this manua l and on the la bels on the vehicle. Al[...]

136 Maintenance Wheel Nut T orque Specifications Check the wheel nut torques occasionally and wh en they've been loo sened for maintenance. Wheel Hub Tightening Front wheel bearing tightness an d spindle nut retention are cr itical componen t operations. All service must be performed by yo ur authorized Polaris dea ler . Wheel Removal 1. Stop [...]

137 Maintenanc e Wheel Inst allation 1. Place the transmission in gear . Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. Never install the rim with the val ve stem to the inside of the vehicle. 3. Install the wheel bolts and finger ti[...]

138 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Main tenance Chart beginning on page 87. Always bleed the clutch system any time the clutch lever feels unrespo nsive. Always use the recommended fluid when blee ding the clutch system. See page 43. 1. Position the vehicle on a level su[...]

139 Maintenanc e Clutch System Bleeding 4. Remove the bleeder screw (2) from the slave cylinder . 5. Press fluid into the system unti l the fluid runs out of the hole (3) in the master cylinder without producing bubbles. Extract fluid from the master cylinder during the process to prevent overflowing. 6. When finished, remove the bleede r syringe. [...]

140 Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay . Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are need ed, use the procedure on page 141. 1/16 " - 1/8" (1.5 - 3 mm)[...]

141 Maintenanc e Throttle Cable Freeplay Adjustment Improper adjustment of throttle cable freep lay can result in loss of control, which could result in se rious injury or death. Polaris recommends that this proc edure be p erformed by a Polaris dealer to ensure that it's done correctly . Mech anically knowledge able persons who perform this p[...]

142 Maintenance Brakes Under normal operation, the diap hragm extends in to the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. T o ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosen ed or removed. Do [...]

143 Maintenanc e Brakes 1. Always maintain brake fluid at the recommended level. See pages 48-49. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or spongy feel. 4. Check the friction pads for wear , damage and loose ness. 5. Check the security and su rface condition of the disc. 6. Inspect the rear brake disc sp[...]

144 Maintenance To e A l i g n m e n t Use the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a ne utral toe setting. W ARNING! Severe injury or death can result from im proper to e alignment a nd ad justment. Do not attempt to adjust tie rod alignmen t. All tie ro d adjustments should be performed by an [...]

145 Maintenanc e To e A l i g n m e n t 3. T ie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of t he rear tire. If available, you may use a long straight- edge instead of string. 4. Measure the distance fro m the string to the rim at the front (1) and rear (2) of t[...]

146 Maintenance Chain T ension Inspection Check the amount of cha in slack by moving the vehicle slightly forwa rd to remove slack at the top side of th e chain. NOTICE: Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmission and drive components can result. Chain tension must be inspe[...]

147 Maintenanc e Chain T ension Inspection 1. Collapse the suspension w ith an adjustable (buckle type) tr ailer tie down strap (1). Fas- ten the strap around the axle and rear bumper tube. 2. T ighten the strap until a straight line (2) can be drawn from the axle to the t ransmission output shaft, intersecting the swing arm pivo t. This establishe[...]

148 Maintenance Chain T ension Adjustment 1. Loosen the two eccentric lo cking bolts. Refer to the illust ration on the following page. 2. Insert a pin punch into the eccentric axle housing. 3. Roll the vehicle slightly to adjust chain slack to the proper dimension. 4. T ighten the eccentric locking bo lts to 35 ft. lbs. (47.5 Nm).[...]

149 Maintenanc e Chain T ension Adjustment Step 1 Step 2 Proper splicelink clip opening position[...]

150 Maintenance Handlebar Adjustment Improper adjustment of the hand leba rs or incorrect torqui ng of the ad juster block tightening bolts can cause limited steeri ng or loosening of the han dlebars, resulting in loss of control. Foll ow the adjustmen t procedures exactly , or see your Polaris dealer for service. The handlebars can be adjusted for[...]

151 Maintenanc e Steering Inspection Check the steering assembly periodically for loos e nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the stee ring post, see your Polaris dealer for service before operating the vehicle. Camber and Caster The camber and caster are non-adjustable.[...]

152 Maintenance Suspension Settings Use a flat -blade screwd river to make da mpin g adjustments. When the adjuster screw is turned clockwise until it stops, the damp ing is in the fully closed position. Rear Shock (S t andard and Limited Edition) Front Shock (Limited Edition) Setting Compression Damping Rebound Damping Softest 20 clicks from close[...]

153 Maintenanc e Front Suspension Compression Damping (Limited Edition) T o adjust the front suspension compression damping, use the adjustment proc edures outlined for the rear suspension compression damping on page 157. Spring Prelo ad The front suspension preload may be adjusted to suit different riding conditions and operator weight. See page 1[...]

154 Maintenance Front Suspension Spring Prelo ad 1. Raise and safely support the front of the vehicle off the ground to allow the suspen sion to fully extend. 2. Loosen the jam nut and back it away from the adjusting ring. 3. T u rn the adjusting ring to th e left (1) to increase preload for a stiffer ride. T urn the adju sting ring to the right (2[...]

155 Maintenanc e Rear Suspension The rear suspension spring preload, shock rebound damp ing and shock compression dampin g may be adjusted to suit different riding conditions and operator weight. Spring Prelo ad 1. Raise and safely support the rear of the vehicle off the ground to allow the suspen sion to fully extend. 2. Loosen the jam nut and bac[...]

156 Maintenance Rear Suspension Rebound Damping Use a flat-blade screwdriver to make damping adjustments. The rebound damping is factory set at 16 clicks from fully closed. See Suspension Settings on page 152. 1. Locate the rebound dam ping clicker drum between the lower spring seat and the lower shock mount. 2. T u rn the clicker counter-clockwise[...]

157 Maintenanc e Rear Suspension Compression Damping Use a flat -blade screwd river to make d amping adjust- ments. The factory setting is at 10 clicks from fully closed. See Suspension Settings on page 152. The compressio n damping clicker is loca ted on top of the shock reservo ir , under the right rear fender . 1. T u rn the clicker clockwise (1[...]

158 Maintenance Cleaning Keeping your vehicle clean will not only impr ove its appearance but it can also extend the life of various components. NOTICE: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will d[...]

159 Maintenanc e Cleaning W ashing the V ehicle Wa shing Tips • A void the use of harsh cleaners, which can scratch the finish. • Do not use a power washer to clean the vehicle. • Do not use medium to heavy duty compounds on the finish. • Always use clean cloths and pads for cleaning and poli shing. Old or reused cloth s and pads may contai[...]

160 Maintenance Cleaning W ashing the V ehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components an d could remove paint and decals. If warning and safety labels are damaged, contact your Pola ris dealer for free replacement. A v oid direct- ing the water stream at the [...]

161 Maintenanc e Polishing Polaris recommends the use of common household aerosol furniture polish for pol ishing the finish on your Polaris vehicle. Fo llow the instructions on the container . Polishing Tips • A void the use of automotive products, some of which can scratch the finish of your vehi- cle. • Always use clean cloths and pads for c[...]

162 Maintenance Sto r ag e NOTICE: S tarting the engin e during the storage period will disturb the protecti ve film created by fogging and damage could occur . Never start the engine during the storage period. Exterior Make necessary repairs and clean the vehicle as recommended. See page 158. Battery Storage Refer to pages 129-134 for ba ttery sto[...]

163 Maintenanc e Sto r ag e Engine Oil Change the oil and both filters. Cl ean the oil screens. See page 100. Air Filter / Air Box Inspect and clean (or replace) the air filter . Clean the air box. Drai n the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as reco mmended in the Period ic Maintenance Chart beginning on pa ge 87. •[...]

164 Maintenance Sto r ag e St abilize the Fuel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel S tabilizer . Follow the instruc- tions on the container for the recommended amou nt. Carb on Clean removes water from fuel systems, stabilizes fue l and removes car bon deposits from pistons, rings, valves and [...]

165 Maintenanc e Sto r ag e Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning on pa ge 87. Storage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable supports under the fra me, raise the vehicle s[...]

166 Maintenance T ransporting the A TV 1. S top the engine. 2. Place the transmission in first gear . 3. Lock the parking brake. 4. Remove the key to preven t loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. T u rn the fuel valve off. 7. Always tie the frame of the A TV to the transporting unit securely with suitable straps or[...]

167 Maintenanc e T ransporting the A TV[...]

168 S pecifications Outlaw 450 MXR Max. Weight Capacity 215 lbs./98 kg Pilot Jet #45 Dry Weight 360 lbs./163 kg Main Jet #138 F uel Capacity 3.1 gal./11.8 l Clip Position 3 Overall Length 71.5 in./182 cm Jet Needle OBDVR Overall Width 47 in./119 cm Alternator Output 200 w @ 3000 RPM Overall Height 45 in./114 cm Compression Ratio 11:1 Wheelbase 50.5[...]

169 S pecifications Outlaw 450 MXR Jetting Chart Outlaw 450 MXR Driving System T ype Rear T wo- Wheel Drive Tire Size - Front 20 x 6R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 18 x 10R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Br ake Hydraulic Disc, Dual Bore Gear Ratio - 2nd 1.941 Rear Br ake Hy[...]

170 S pecifications Outlaw 525 S Max. Weight Capacity 215 lbs./98 kg Pilot Jet #45 Dry Weight 370 lbs./168 kg Main Jet #138 F uel Capacity 3.1 gal./11.8 l Clip Position 4 Overall Length 71.5 in./182 cm Jet Needle OBDVS Overall Width 47.5 in./121 cm Alternator Output 200 w @ 3000 RPM Overall Height 45 in./114 cm Compression Ratio 11:1 Wheelbase 50.5[...]

171 S pecifications Outlaw 525 S Jetting Chart Outlaw 525 S Driving System T ype Rear T wo- Wheel Drive Tire Size - Front 21 x 7R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 20 x 11R9 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Br ake Hydraulic Disc, Dual Bore Gear Ratio - 2nd 1.941 Rear Br ake Hydrau[...]

172 Polaris Product s P art Number Desc ription Engine Lubr icant 2876244 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Synthetic 2W-50 4-Cycle Oil (gal.) Grease / Specia lized Lubricants 2871312 Grease Gun Kit, Pre mium All Season (3 oz.) 2871322 Premium All Season Grease (3 oz. cartridge) 2871423 Premium [...]

173 Polaris Product s P art Number Descr iption Coolant 2871323 60/40 Coolant (gal.) 2871534 60/40 Coolant (qt.) Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT4 Bra ke Fluid (12 oz.) 2876335 Hydraulic C lutch Oil (qt.)[...]

174 T roubleshooting See your Polaris dealer if you're unable to identify solutions using the following charts. Engine T urns Over , Fails to S t art Possible Caus e Solution Out of fuel T urn the fuel valve to reserve, ref uel W ater is present in carburetor or fuel supply Cle an carburetor and/or drai n fuel system and refuel Fuel valve is t[...]

175 T roubleshooting Engine T urns Over , Fails to S t art Possible Caus e Solution No spark to spark plug Inspect, clean and/or replace spark plugs See your Polaris dealer Overuse of choke/flooded engine Engage starter 2 times for 5 seconds each, then restart. If engine f ails to start, i n spect, clean and/or replace spark plugs. Low battery volt[...]

176 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Cause Solution Fuseable link See Polari s dealer for replacement Low battery voltage Rechar ge battery to 12.8 VDC Loose battery connections Chec k all connections an d tighten Loose solenoid connections Chec k all connections an d tighten Possible Cause Solution Poor [...]

177 T roubleshooting Engine Backfires Possible Cause Solution W eak, fouled or defective spark plug In spect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel R eplace with new fuel Exhaust leak Inspect system for leaks; see your Polaris dealer Incorrectly installe[...]

178 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Fouled or defective spark plug Inspec t, clean and/or replace spark plug W orn or defective spark pl ug wire See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connect ions Check all connections and [...]

179 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Cause Solution Clogged air filter Inspect and clean or replace Electronic throttle control ma lfunction See your Polaris dealer Incorrect idle adjustment Adjust id le speed or see your Polaris dealer Clogged idle jet Disassemble ca rburetor and clean the jets Other mechanic[...]

180 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Lean F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean the fuel system Low octane fuel Replace with recommended fuel Old or non-recommended fuel R e place with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jettin[...]

181 T roubleshooting Engine Fails to Reach High RPM Engine Uses Excessive Oil Possible Cause Solution W orn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets T ighten jets Faulty ignition timing See your Polaris dealer Possible Cause Solution Bent engine ventilatio n hose Install a new hose Excessive oil in system Check [...]

182 T roubleshooting Engine Stop s or Loses Power Possible Cause Solution Out of fuel T urn the fuel valve to reserve, ref uel Interrupted fuel supply Clean fuel system and carburetor Clogged, dirty or wet air filter I nspect and clean or replace Electronic throttle control ma lfunction See your Polaris dealer Other mechanical failure See your Pola[...]

183 T roubleshooting Engine Stop s or Loses Power Possible Cause Solution Kinked or plugged fuel vent line Inspect and replace W ater present in fuel Replace with new fuel Overuse of choke Ins pect, clea n a nd/or replace spark plugs Fouled or defective spark plug Inspec t, clean and/or replace spark plugs W orn or defective spark pl ug wire See yo[...]

184 T roubleshooting Engine Overheat s Possible Cause Solution Debris lodged in radiator scre en Remove and clean the screen Plugged radiator Use a garden hose to flush any debris from the radia- tor fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency . Insufficient coolant Check levels a nd fill as needed; [...]

185 T roubleshooting Engine Fails to Reach Full Power Possible Cause Solution Interrupted fuel supply Clean fuel system and carburetor Float leak s Replace t he float Clogged, dirty or wet air filter I nspect and clean or replace Faulty exhaust system Check system for damage; see your Polaris dealer V alve gap is too small Adjust valve gap Faulty i[...]

186 Wa r r a n t y LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of the Polaris All T errain V ehi cle (A TV) agai nst defe cts in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warra nty[...]

187 W arranty WARRANTY COVERAGE AND EXCL U SIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris limi ted warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accident al damage, normal wear and tear, a buse or improper ha ndling. This war- ranty also does not cover any A TV t[...]

188 Wa r r a n t y WARRANTY COVERAGE AND EX CLUSIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLU DING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCLAIMS ALL EXPRE SS W ARRANT[...]

189 W arranty HOW TO OBT AIN WARRANTY SERVICE If your A TV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris A TVs. When requesting warranty service you mu st present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). [...]

190 Wa r r a n t y EXPORTED VEHICLES EXCEP T WHERE SP ECIFICALL Y REQUIRE D BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA TIO N. This policy does not apply to vehicles that have received authorization for export from Po laris Industries[...]

191 W arranty EXPORTED VEHICLES How to Get Servic e I n the country wh ere your vehi cle was purchase d: W arranty or Service Bulletin repairs must be done by an authorized Polar is dealer . If you move or are traveling within the country where your vehicle was purchased, W a rranty or Service Bulletin repairs may be requested from any authorized P[...]

192 Wa r r a n t y EXPORTED VEHICLES How to Get Servic e If Purchased From A Private Party: If you purchase a Polaris product from a pr ivate citizen out side of the country in whic h the vehicle was originally purchased, all warranty cove rage will be denied. Notice If your vehicle is registered outside of the country wher e it was purchased, and [...]

193 W arranty U.S.A. EP A Emissions Limited W arranty This All T errain V ehicle (A TV) or Off Road Utility V ehicle (ORUV) emissions limited warranty is in addition to the Polar is standard limite d warranty for this vehicle. Polaris warrants that this vehicle is ; (1 ) designed, built, and equipped to conf orm at the time of initial sa le with th[...]

194 Wa r r a n t y U.S.A. EP A Emissions Limited W arranty The exclusive remedy for bre ach of this limited warranty shall be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products. THE REMEDIES SET FOR TH IN THIS LIM- ITED W ARRANTY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH[...]

195 Maintenance Log Present this section of your manual to your dealer each time your vehicle is serviced . This will provide you and future owners with an accurate log of maintenance and services performed. DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 3 Hours (Break-in) 15 30 45[...]

196 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS 60 90[...]

197 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

198 Maintenance Log DA TE SERVICE INTERVAL (HOURS) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

199 Index A Age Restrictions . . . . . . . . . . . . . . 15 Air Filter Systems . . . . . . . . . . . . 112 B Battery Charging . . . . . . . . . . . . 132-1 34 Installation . . . . . . . . . . . . . 131 Maintenance . . . . . . . . . . . . 129 Removal . . . . . . . . . . . . . . . 130 Storage . . . . . . . . . . . . 130, 162 Bleeding the Cooling Syst[...]

200 Index F Fluid Brake . . . . . . . . . . . . . . . . 48-49 Clutch . . . . . . . . . . . . . . . . . . 43 Foot Brake . . . . . . . . . . . . . . . . . . . 46 Foot Brake Fluid Lev el . . . . . . . . . 49 Fuel Filter . . . . . . . . . . . . . . . . . . . . 56 Fuel Safety . . . . . . . . . . . . . . . . . . . 17 Fuel Stabilizer . . . . . . . . . . .[...]

201 Index R Rebound Dampin g, Rear . . . . . . . 156 Restrictions, Age . . . . . . . . . . . . . . 15 Reverse Lock-Out Switch . . . . . . . 54 Riding Area . . . . . . . . . . . . . . . . . . 64 Riding Gear . . . . . . . . . . . . . . . . 13-14 S Safe Operation Practices . . . . . . 62-63 Safety Labels and Locations . 34-37 Age 16 Warning . . . . . [...]

202 Index S Spark Arrestor Clean -Out. . . 124-125 Spark Plugs . . . . . . . . . . . . . . 122 -123 Spring Preload . . . . . . . . . . . . . . . 153 Spring Preload , Front . . . . . . . . . . 154 Spring Preload, Rear . . . . . . . . . . 155 Starting the Eng ine . . . . . . . . . . 66, 67 Steering Inspection . . . . . . . . . . . . 151 Storage . . .[...]