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

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

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

5 TABL E OF CONTENT S VEHICLE I DENTI FI CA T ION NUM BERS 6 .............................. SAF ETY 8 ......................................................... FEA T URES AND CONTROL S 50 ..................................... OPE RA T ION 69 .................................................... EMI SSION CO NTRO L SYST EMS 92 .......................[...]

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

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

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

9 SA FE TY Safety D ecals an d Locatio ns Locat ion B Locat ion C 7172560 E 1997, 2000 IF OWNE R’S MANUAL IS MISSI NG, CONT ACT A POLARIS DEALER FOR A REPL ACEMENT . W ARNING Operat ing this A TV if you are under the age of 16 i ncreases your chan ce of severe i nj ury or death. NEVER ope ra te t his ATV if yo u are under age 1 6. 7172559 W ARNIN[...]

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

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

E 4 051039 0006.031 12 SA FE TY Sa fe Riding Gea r Always we ar c lothing suited to the type of r idi ng. A TV riding re quires prote ctive c lothing for comf ort and t o reduc e the chance of injur y . 1. Helmet W ea ring a helmet ca n preve nt a se vere hea d injury . Whene ver riding a Polar is vehicle , alway s wear a h elm et th at m eets or e[...]

13 SA FE TY Sa fe Riding Gea r 2. Eye Prot ection Do not depend on sungla sses for prope r eye pr otection. W ea r shatterpr oof goggles or a shatter proof helme t fac e shield. 3. Gloves Of f-road st yle gloves with knuckle pads are the best for comf ort and prote ction. 4. Boots The best footwe ar is a pair of strong over -the- calf boots with he[...]

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 Operat or Rest rict ion s This vehicle is an ADUL T VEHICLE ONL Y . Operation i s prohibit ed for anyone unde r 16 yea rs of age. This c ategor y S (Sport) A TV is a high per formance ve hicle intended for of f roa d use only , for sport- type rec rea tion and f or c ompetitive use by ope rators w ith advanc ed skills a[...]

16 SA FE TY Sa fety T r ai ning A TV saf ety training is a top pr iority for Polaris. When you pur chase d your new A TV , your deal er ins tru cted y ou o n th e autho ri zed A TV RiderCourse sm a vailable to you and your eligible f amily member s. This tra ining is include d in the purcha se price of your A TV . Polaris str ongly encoura ges you [...]

17 SA FE TY Sa fety T r ai ning A P olari s A TV i s an o f f-ro ad veh icl e. F a miliariz e yourself with a l l laws a nd regula tions conc erning the ope ration of this vehicle in your a rea. Follow the re commende d m ainte nance progra m outlined in your owne r ’ s manual. This progra m is designed to ensure that all c r itica l components o[...]

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

19 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.[...]

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

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

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

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

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

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

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

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

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

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

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

31 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[...]

32 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[...]

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

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

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

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

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

38 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 [...]

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

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

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

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

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

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

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

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

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

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

49 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[...]

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

51 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[...]

52 FEAT URES AND CONTROL S In s t rume n t at i on An illumina ted light in the indic ator window will a lert you to the f ollowing conditions. 1. Hot engine 2. Rev erse g ear is sel ected 3. Neu tral gear i s s elect ed N R 3 1 2[...]

53 FEAT URES AND CONTROL S Lights W ARNING Oper ating t he A T V on s tr eets or roads , es pecially in darknes s, could res ult in an ac cident and seri ous injury or deat h. Y our A T V is not equipped wit h highway- approved lights . I t ’ s designed f or and mus t be us ed for off -road use only . Use c aution and dr ive at reduced s peeds in[...]

54 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[...]

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

56 FEAT URES AND CONTROL S Foot Br ake The foot brake ( 1) operate s the re ar brake s. It’ s located in front of the right- hand footpeg ( 2). If the re ar whe els slide while using the foot brake, r educ e bra ke peda l pre ssure to brake the whee l s without skidding. Check the bra ke fluid l eve l fr equently for the foot brake system. The re[...]

57 FEAT URES AND CONTROL S Br ake L ever The bra ke lever oper ates the front brake s. It’ s l oca ted on the r ight han dleb ar . S queeze t he b rake l ever t oward th e hand leb ar to eng age the front bra kes. These bra kes are hydr aulic ally activa t ed disc type brak es. Alway s t est brake l ever t ravel and mas ter cy li nder fl ui d l e[...]

58 FEAT URES AND CONTROL S Master Cylinder The maste r cylinder (1) is on the rig ht -hand h andl ebar . C heck t he brak e flu id level befo re each ri de. The fl ui d leve l ca n be seen thr ough the indicator window (2) on the top of t he maste r cylinde r . This eye wil l app ear dark wh en the f luid leve l i s full. W hen f luid need s to be [...]

59 FEAT URES AND CONTROL S Master Cylinder W ARNING Ov erf illing the m ast er cy linder will res ult in br ake f ailure. W it hout r oom t o expand, the exces s f luid will cause t he brak es t o apply aut omat ically , which c ould result in ser ious injury or death. Alway s maint ain t he fluid lev el between t he MI N and MA X mar ks. Af ter op[...]

60 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 Par king Brake 1. Place the tr ansmission in f i rst gea r or neutr al. 2. S queeze a[...]

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

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

63 FEAT URES AND CONTROL S Fuel V alve The fu el v alv e (1) i s l ocat ed o n th e left s ide o f the A TV . It has three positions: OFF : F or veh icl e st orage an d when tra nsporting. ON: For normal opera tion. RES: F or r eserve supply if main supply is exha usted. NOT E: T here’s about a 5 t o 8 mile ( 8 to 13 k m) r ange on reser ve gas. [...]

64 FEAT URES AND CONTROL S Chok e The choke a ssists in star ting a cold engine . The choke knob (1) is l oca t ed on the left side of the vehicle. Refe r t o the engine star ting pr oce dure on page 74 for corr ec t choke and throttle se ttings dur ing starting. 1[...]

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

66 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. Whe n starting f rom a stopped position, plac e the tra nsmission in neutral. 2. S queeze an d h ol d t he brak e lev er . NOT E: Do not squeez e the t hrot t le lever . 3. S queeze t he cl ut ch l ever t o d is en[...]

67 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. Place the tr ansmission in first gear . See page 65. 2. Push the l ock- out leve r forw ard toward the handle bar to unlock the tra nsmission. 3. Shift down into reve r[...]

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

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

70 OPERATION Br eak - In Period Car eful tre atment of a n ew engine and tr ansmission will r esult in more ef fic ient per forma nce and longer life f or both. The brea k-in period for your new Polaris A TV i s 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 per iod [...]

71 OPERATION Br eak - In Period 1. Fill the fuel tank with gasoline . See pa ge 62. 2. Check t he oil l evel on the dipst ick. S ee page 105. Add o il if necess ary to maint ain the lev el bet ween th e safe and add m arks. 3. Allow the engine suf fic ient time to warm up befor e oper ating. 4. Dr ive slow ly at fir st. Selec t an open a re a that [...]

72 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 57, 147[...]

73 OPERATION Pr e - Ride Insp ection Pre - Ri de Chec kl is t See Page Fram e nut s, bolts, f astener s Inspect , ensure ti ghtness -- Fuel and oil Ensure proper l evels 105 Coolant l evel (i f applicabl e) Ensure proper l evel 11 4 Coolant hoses (i f appli cable) Inspect f or leaks -- Th ro ttle Ensure proper oper ati on 54, 164 Indi cator l ights[...]

74 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[...]

75 OPERATION St ar ting a Col d Engine 3. Sit on the A TV . P ull the c hoke knob (1 ) out until it stops. NOT E: I f the k nob doesn’t st ay where pos itioned, increas e the t ension by rot ating t he t ension adjust ing nut c lockwis e. FULL ON HALF ON OFF NOT E: T he chok e can be adjust ed gradually , depending on how muc h choke is needed fo[...]

76 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 65. 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[...]

77 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[...]

78 OPERATION Driving Safely Drivin g Procedures 1. Sit upright with both feet on the footpegs a nd both hands on the handleba rs. 2. Start the e ngine and allow it to warm up, then shift the transmission into gea r . S ee pa ge 66. 3. Check your surroundings a nd determine your path of tra vel. 4. Relea se the parking brake . 5. Slowly depre ss the[...]

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

80 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 nter ing slippery a reas. 2. Mainta in a high leve l of a lertness, re ading the tra il and avoiding quic k, shar p turns[...]

81 OPERATION Driving Safely Drivin g Uphill Whe never tr aveling uphill, follow these pr ecauti on s: 1. Alwa ys trave l straight uphill. 2. A void stee p hills (25 _ ma ximum). 3. Kee p both feet on the f ootpegs and transf er your weight forwa rd. 4. P roceed at a st eady rat e of sp eed and t hro ttle opening. 5. Be al ert and p repared t o tak [...]

82 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[...]

83 OPERATION Driving Safely Drivin g Downh ill Whe never de scending a hill, follow these precau ti on s: 1. P roceed di rect ly d ownh ill. 2. T ransfe r your weight to the re ar of the vehic le. 3. Slow down. 4. Shift to the lowe st gear possible while mainta ining a safe spe ed. 5. Apply the foot bra ke slightly t oa i di ns l o w i n g . W ARNI[...]

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

85 OPERATION Driving Safely T urni ng 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 br ake. 6. W ith the front brake s applied, pull in the clutch leve r . Use the brakes to slowly allow the vehicle to roll a round to your r ight unt[...]

86 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on a n incline if possible. If it’ s una voidable, fol lo w th ese p recaut ion s: 1. T urn the engine of f. 2. Place the tr ansmission in firs t gear . 3. Lock the parking br ake. 4. Always block the rea r whee l s on the downhill side. See illustra tion. 5. Shut of f th[...]

87 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[...]

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

89 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[...]

90 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 back ing downhill. 2. Bac k slowly . 3. Apply the brakes lightly for stopping. 4. A void turning at shar p angle s. 5. Ne ver ope n the throttle sudde nly while bac king.[...]

91 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[...]

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

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

94 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. Ke ep[...]

95 MAINT ENANCE AND LUBRICATION P er iodic Mai ntenance S chedule Severe Use Defi n it io n S Fre quent immersion in mud, wa ter or san d S Raci ng o r race-sty le hi gh R P M us e S Prolonged low spe ed, heavy load ope ration S Extende d i dle S Short trip cold we ather ope ration Ins pect , cl ean, l ub ricat e, ad ju st an d repl ace parts as ne[...]

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

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) Br ake syst e m s/fl ui d -- Pre- Ride -- Ins pec t; maint ain fluid between f ill lines Ti r es -- P re-R ide -- Ins pec t Wheels /lug nuts -- Pre- Ride -- Ins pec t; tight en Frame fas t eners -[...]

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) " Steer ing -- Pre- Ride -- C heck f or free oper ation and loos e c ompo- nents " Air box s ediment tubes -- Pr e-Ride -- D rain depos its w hen v isible Headlamp -- P re-R ide -- Chec [...]

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) " E Air filter , main element -- W eek ly -- Ins pect ; clean; r eplac 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) Perfo[...]

100 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 torage J E Thrott le Cable/E TC Switch 50 H 6M 500 (800) Ins pec t; adjus t; replac e if neces s ary E Chok e (e[...]

101 MAINTENANCE AND L UBRICATION Per iod ic Mainten ance Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) " F Upper s teer ing pos t (A) 50 H 3M 500 (800) I nspec t; t ighten fas teners ; gr ease af ter was hing A TV or dr iving in w ater " F Front A-Arm s (B) 50 H 3M 500 (800) I nspec t; t[...]

102 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) P re ssur e test syst em an[...]

103 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) Ins pec t; c lean ex ternal s ur face; c hange c oolant ev ery 2 y ears " Co ol in g syste m h ose s 100 H 12 M 1000 (1600) Inspec t Engine mounts 100 H 12 M [...]

104 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[...]

105 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 an d let it idle for one minute . 3. Stop the engine and remove the dipstic k. W ipe it dry with a cle an cloth. 4. [...]

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

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

108 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 1. Position the vehicle on a leve l surf ace. 2. Clean the ar ea ar ound the oil ta nk (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 bene ath the oil tank and re move the d[...]

109 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 7. Place a dr ain pan benea t h the cra nkca se and remove the dra in plug. 8. Allow the oil to dra in complete ly . 9. Replac e the se aling wa sher and r einstall the plug. T orque to 14 ft. lbs. (19 Nm). 10. Place shop towe ls be nea th the oil filter . 1 1. Remove the three cove r bolts [...]

11 0 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 14. Replace the o- ring in the c over . 15. Lubrica te t he gaske t on the new f ilter with a film of fresh engine oil. 16. Reinstall the spr i ng an d install the ne w filter with the ope n end fa cing outwar d. 17. Install the c over a nd torque the bolts to 72- 78 in. lbs. (8-9 Nm). NOT [...]

111 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 18. Remove the dipstick a nd fill the oil tank w ith the rec ommende d oil. 19. P lac e the tra nsmission in neutral. Loc k the parking br ake. 20. Pr ime t he oil pump using the pr oc edur e on page 1 12 . Then stop t he engine a nd in sp ect for l eaks . 21. Re-che ck the oil le vel on the[...]

11 2 MAINT ENANCE AND LUBRICATION Oil Pump Pr iming This priming proc edure must be perf ormed whene ver the oil hose conne ction betwe en the oil tank a nd pump inlet has b een di sco nnect ed. 1. Clamp or pinch of f the vent line (1) approxima tely 2 I (5 c m ) f rom the oil tank. 2. Run the engine for 5-10 sec onds at idle. Stop the engine and r[...]

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

11 4 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem Co olant L evel The re cover y bottle (1) is l oca ted on the r ight side of the vehic l e under the fr ont fe nder . The fluid leve l must be mainta ined betwe en the FULL ( 2) and AD D (3) ma rks on the side pane l (w hen t he fluid is cool). As co olan t o perat in g t emperat ure i ncre[...]

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

11 6 MAINT ENANCE AND LUBRICATION Air Filter System s 1. Unlatc h a nd re move the seat. 2. Relea se the two a irbox cove r clips (1) and rota t e the cove r rear ward to remove it. 3. Remove the a ir filter re taining scre w (2). 4. Loose n the filter cla mp (3). 5. Remove the ma in a ir filter (4) . 6. Remove the p re -filter ( 5) from the main f[...]

11 7 MAINT ENANCE AND LUBRICATION Air Filter System s 9. W ash the ma in filter ele ment (4) without re moving it from the inter nal filte r ca ge. Rinse and le t dry . Whe n dry , apply Pure Polar is foa m filter oil thor oughly t o the e l eme nt. 10. Reinstall all c omponents. 1 1. Check th e ho ses for cracks, d eteri orat io n, abras i on, o r[...]

11 8 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 9 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 lef t headlamp, gra sp 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 d iel[...]

120 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 cab (see pa ge 123). Position the ca b upside down on a soft pro tect iv e su rface to preven t s cratch in g. 3. Remove the sma ll a djuster brac ket (1) and install it on the new la mp. 4. Rem[...]

121 MAINT ENANCE AND LUBRICATION Lights Head light A ssembly Replacem ent 5. Insta l l the new hea dlamp by inserting the outboar d pivot pin in the hole of the mounting tab on the c ab. 6. Insta l l the adjuster bra cket onto the inboard pivot pin of the hea dlamp. 7. Adjust for approxima tely 1/16” clear ance be tween the brac ket and the edge [...]

122 MAINT ENANCE AND LUBRICATION Lights Head light Ad justmen t 1. Position the A TV on a level surfa ce with the hea dlight appr oximately 25 ft. (7.6 m) f rom a f lat wall. 2. Mea sure the distance f rom t he floor to the ce nter 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 headlight sw[...]

123 MAINT ENANCE AND LUBRICATION Fr ont Cab Re m oval 1. Remove the scr ews (1) from the lef t and right cab mounts. 2. Remove the wir e harness conne ctor from the cab. The conne ctor is loc ated unde r the left fende r . 3. Loosen the fuel tank c over scre ws (2). 4. Remove the four side pa nel s cr ews (3). 5. Gently pull the c ab upward to dise[...]

124 MAINT ENANCE AND LUBRICATION Rear Cab Removal 1. Unlatc h a nd re move the seat. 2. Remove the two lower bolts (1) on t he re ar fende rs of the c ab and the two bolts (2) , washe rs and gr ommets (3) on the top of the ca b. 3. Remove the ca b. 3 2 1[...]

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

126 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[...]

127 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 1. Remove the side pane l s and front cab (se e page 123). 2. T urn the fuel valve of f. W ARNING A hot ember on t he A T V c ould cause f uel t o ignite. Allow all c omponent s t o cool suffic iently befor e acces sing t he spark plug. A lways ex ercis e ext reme c[...]

128 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 3. Move the fue l valve hose c lamp (1) forwa rd and gently re move the hose from the fuel valve f itting on t he gas tank. 4. Remove the ve nt hose (2) from the steer ing post, taking note of the hose routing for re installation. 2 1 3[...]

129 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 5. Remove the tank mounting bolt (3) at the rear of the ga s ta nk. 6. Move the tank rea rward a nd upward over the engine. Slowly remove the tank a nd be ca reful not to ca tch any hose s, wire s or other c omponents. P lac e the tank on a stable surfa ce or work b[...]

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

131 MAINT ENANCE AND LUBRICATION Spar k Ar restor Cl ean - Out Periodic ally cle an the spar k ar restor to r emove accumul ated carbon. 1. Remove the three sc rews (1) and re move the arrest or (2) fro m t he end of t he mu f fl er . 2. Use a non-synthe tic brush t o cle an the ar restor sc reen ( 3). A synthetic br ush may melt if component s are[...]

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

133 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n 1. T urn the fuel valve of f. 2. Dra in wa ter from the air box and cle an the air f ilter ( if equippe d). S ee pa ge 1 16. 3. Drain the fue l/water f rom the car buretor f or about 10 seconds. 4. Remove the spar k plug. See page 127. W ARNING Fluids will be eject ed thr ough the s park plu[...]

134 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n 6. Press a nd hold t he sta rter button f or 10 second inte rvals for about one minute or until wate r vapor is no longe r e jec ting from the spar k plug hole. 7. Chec k the oil level on the dipstick. If the leve l is higher than the pre -ride inspec tion leve l, wate r has enter ed the oil[...]

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

136 MAINT ENANCE AND LUBRICATION Batter y Stor age When t he vehicl e is placed i n st orage for th ree m onths or m ore, the battery should be remo ved and s to red ou t of th e sun i n a cool , d ry pl ace. T est and rech ar ge th e batt ery monthly and be fore r eusing. Batt ery Remov al 1. Remove the fr ont ca b (see page 123) a nd disc onnect [...]

137 MAINT ENANCE AND LUBRICATION Battery Installation 1. Plac e the batte ry in the batte ry holder . 2. Connec t and tighten the re d (positive ) cable fir st, then c onnect and tighte n the blac k (neg ati ve) cabl e. 3. Attac h the hold-down stra p and re install the f ront ca b. 4. V er ify that c ables ar e proper l y route d. NOT E: W hen ins[...]

138 MAINT ENANCE AND LUBRICATION Batter y Charging (S ealed Batter y) The ba ttery include d with your A TV is sea l ed a nd the sea ling strip c annot be r emoved. Use a voltmete r or multimeter to me asur e DC voltage. A fully c har ged batte ry will registe r 12. 8 V or higher . If the volta ge is less than 12. 8 volts, r ec har ge the batte ry [...]

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

140 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 [...]

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

142 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. Never ins tall t he rim with t he valv e st em t o the inside of the v ehicle. Always ensur e that all nut s are t orqued t o specif icat ion. 1. Place th[...]

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

144 MAINT ENANCE AND LUBRICATION Boot Insp ection Befo re Op erati n g Inspe ct the boots bef ore opera ting the vehic le. If a boot is torn, puncture d or leaking f luid, see your P olari s d ealer fo r serv ice or rep lacem ent . Good Boot After Opera ti ng Inspe ct the boots after ope ra ting the vehicle. If a boot is bulging or ballooned, per f[...]

145 MAINT ENANCE AND LUBRICATION Boot B urping 1. Using a needle nose plie rs or boot cla mp removal tool, remove the sma ll boot clamp (1) from the inboar d boot. NOT E: Do not use any tools that may damage t he boot. 2. Slide the free e nd of the boot two i nche s towar d the ce nter of the vehicle a nd lift t he boot awa y from the sh aft to al [...]

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

147 ADJUST MENTS Br akes 1. Always mainta in the br ake fluid at an adequa te level (see pa ge 58). 2. C h eck t he brak e sys t em for flu id leak s. 3. Check the bra kes for exce ssive trave l or spongy fee l. 4. C h eck the fri cti on p ads for wear , d amag e and lo os eness . 5. Chec k the sec urity and surf ace condition of the disc. 6. In sp[...]

148 ADJUST MENTS W ARNING Sever e injury or death c an result f rom im proper toe alignm ent and adjus tm ent. Do not att empt t o adjust tie r od alignment . All tie r od adjust ments should be per for med by an author ized Polar is dealer . T oe Alignm ent Use the following proc edur e to chec k toe a lignment. The ve hicle is designe d f or a ne[...]

149 ADJUST MENTS T oe Alignm ent 4. T ie an elastic str ing (2) ar ound the stands, making 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 . 5. Mea sure the distance be tween the string in front of the re ar tires (A ) and in front of the front [...]

150 ADJUST MENTS Chain T ension CAUTION Never adjus t or operat e the v ehicle wit h the r ear driv e chain t oo loose or t oo t ight. Sever e damage t o the t rans miss ion and drive c omponent s can r esult . Chec k the amount of c hain sla ck by moving the ve hicle slightly for ward to r emove slac k at the top side of the chain. At the cente r [...]

151 ADJUST MENTS Chain T ension 1. Loosen the upper a nd lower pivot mounting bolts (1). 2. Thr ea d the chain a djusting bolt (2) inwa rd or outwa rd to adjust cha in slack to the prope r dimension. 3. T i ghten the pivot mounting bolts to 30 ft. lbs. (40 Nm) . 4. T orque the cha in adjusting bolt to 17 ft. lbs. (2 3 Nm). Proper Spl icel ink Cli p[...]

152 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 [...]

153 ADJUST MENTS Steer in g Assem b ly The ste er ing assembly of the A TV should be c hecke d periodica lly for loose nuts and bolts. If loose nuts and bolts a re found, or if you notic e any fr eepla y i n the ste ering post, see your Polaris dea l er f or service be fore ope ra ting the vehicle. Cam b er and Caster The ca m ber a nd c aster ar e[...]

154 ADJUST MENTS Fr ont Suspens ion Susp ension Set- Up 1. Position the vehicle on a leve l surf ace. 2. Stop the engine. 3. Eleva te t he fr ont of the vehic le by pla cing a suitable sta nd unde r the frame . NOT E: T he t ires s hould be barely t ouching t he ground and t he suspens ion should be at full r ebound. 4. Mea sure the distance f rom [...]

155 ADJUST MENTS Fr ont Suspens ion Susp ension Set- Up 6. Place the tra nsmission in neutral a nd slowly roll the machine for war d and r earwa rd at lea st ten f ee t (3 m) without lifting or pushing down on the suspe nsion. 7. T urn the ha ndlebar s fully to the le ft and right. 8. W ith the ride r still on the veh icle , re peat the me asure me[...]

156 ADJUST MENTS Fr ont Suspens ion Spring Prelo a d The f ront suspension pr eload may be adjuste d to suit dif fe re nt riding conditions a nd oper ator we ight. W ARNING Uneven adjust ment may cause poor handling of the A T V , which could r esult in an accident and ser ious injury or deat h. A lways adjus t bot h t he left and right spr ing pre[...]

157 ADJUST MENTS Fr ont Suspens ion Spring Prelo a d 1. Raise and saf ely support t he fr ont of the A TV of f the ground to a llow the suspension to fu lly exte nd. 2. Loosen the jam nut (1) . 3. T urn the adjusting r ing (2) clockwise to incre ase preloa d (A). T urn the r i ng counte r- clockwise to decreas e prelo ad (B ). 4. T i ghten the jam [...]

158 ADJUST MENTS Rear S uspen sion Susp ension Set- Up 1. Position the vehicle on a leve l surf ace. 2. Stop the engine. 3. El evat e th e rear of t he v ehi cle by pl acin g a suitable sta nd unde r the frame . NOT E: T he t ires s hould be barely t ouching the gr ound and the s uspension should be at full r ebound. 4. Mea sure the distance f rom [...]

159 ADJUST MENTS Rear S uspen sion Susp ension Set- Up 5. Remove the stand a nd have a ride r sit comf ortably on the se at with hands on the handle bars. 6. Place the tra nsmission in neutral a nd slowly roll the machine for war d and r earwa rd at lea st ten f ee t (3 m) without lifting or pushing down on the suspe nsion. 7. T urn the ha ndlebar [...]

160 ADJUST MENTS Rear S uspen sion 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. Rear Sh ock Se ttin g Compr ession Dampi ng So fte st 18 clicks f rom cl osed Factor y 8 cli cks fr om closed Fir mest 2 cli cks [...]

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

1 A B 162 ADJUST MENTS Rear S uspen sion Co mpression D amping The c ompression damping c lickers ( 1) are loca t ed on top of the shocks (under the r ear fe nders). Use a sc rewdr iver to make adjustme nts. T o incre ase compr ession damping, turn the clicker c lockwise (A ). T o dec rease c ompression damping, turn the clicke r counte r- clockwis[...]

163 ADJUST MENTS Clutch Lever Freeplay 1. M easu re clut ch l ever freepl ay between the per ch and the leve r (A). This distanc e should be 1/8 ″ -3 / 1 6 ″ (3.1 mm - 4 .7 mm). 2. If a djustment is re quired, 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 e[...]

164 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[...]

165 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 ar m up the engine by running the vehic le for five minutes, or u nt il operat i ng t emp eratu re is reached . 2. Apply the pa rk bra ke and pla ce the tr ansmission in neutra[...]

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

167 CLEANING AND ST ORAGE NOT E: S ee page 181 for the par t num bers of Polar is produc ts . Cleaning th e A TV Kee ping your A TV cle an will not only improve its appe ara nce but it ca n also exte nd the life of var ious components. W ash ing th e A TV CAUTION Do not us e a high press ure washer for washing t he A T V . Ser ious damage will r es[...]

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

169 CLEANING AND ST ORAGE St or age Recom me ndations CAUTION St art ing the engine dur ing the s tor age period will dist urb t he prot ect ive f ilm c reat ed by fogging and dam age could occ ur . Nev er st art the engine dur ing the s tor age period. Clean t he Exterio r Make nece ssary re pairs and the n clean the A TV thoroughly a s outlined o[...]

170 CLEANING AND ST ORAGE St or age Recom me ndations Oil and Filt er W ar m the engine and cha nge the oil a nd filter . See pa ge 107. Air F ilter / Air Bo x Inspe ct and c lean or re place the pr e-c lea ner a nd air f ilter . Clea n the air box a nd dra in the sedime nt tube. Br eath er Filter Inspe ct and clea n or re place the br eathe r filt[...]

171 CLEANING AND ST ORAGE St or age Recom me ndations Fog the E ngine 1. Start the engine and allow it to wa rm up. T urn engine of f. 2. Unlatc h a nd re move the seat. 3. Loosen the intake duc t cla mp a t the carbur etor and pull the duc t off the c arbure tor . 4. Start the engine and spra y Polar is fogging oil or a compa rable produc t into t[...]

172 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[...]

173 CLEANING AND ST ORAGE T ranspor ting the A TV Follow these pr ocedure s when transpor ting the vehic l e. 1. T urn off the e ngine and re m ove the key to pre vent loss during tra nsporting. 2. T urn the fuel valve of f. 3. Be s ure t he fu el cap , oil cap and s eat are installe d corr ectly . 4. Alwa ys tie the frame of the A TV to the tra ns[...]

174 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 conne ct ions Ch eck [...]

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

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

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

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

179 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[...]

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

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

182 SPECIF ICATIO NS OUTLA W Gro ss V e hic le W eig h t 645 lbs ./292 kg Pilot J et 37.5 Fuel C apacity 3.25 gal ./ 12.3 l Main J et 145 Overal l Length 71.5 i n./ 182 cm Needle Je t O- 0 Overal l Wi dth 47. 5 in. /121 cm J et Needle 6GL68- 40 - #2 Overal l Height 45 in. /1 14 cm Al ternat or Output 200 w @ 3000 R PM Wheel base 51 in./ 130 cm Com [...]

183 SPECIF ICATIO NS OUTLA W Driv ing Sy ste m T yp e Rear T wo - Wheel Dri v e T ire Si ze/Pressure - Front 2 1x7 R 1 0/5p s i S hif t T ype 5 - Speed Manual S hift T ire Si ze/Pr essure - Rear 2 0x1 0 R 9/5p s i Prima ry Ra tio 2. 880 F ront B rake Hydraulic Disc Gear Rat io - 1 st 2.357 R ear Brake Hydrau lic Di sc Gear Rati o - 2nd 1.867 P a rk[...]

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

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

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

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

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

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

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

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

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

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

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

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

196 Index A Air Filter Sy ste ms 116 - 11 7 ....... B Batte ry 13 5 .................. Bat tery C har ging 138 - 139 ........ Batte ry In stalla tion 13 7 ......... Bat tery R emoval 136 ........... Bat ter y S tor age 136 ............ Boo t Burp ing 14 5 ............. Boo t In spe ctio n 14 4 ............ Brak e Fluid 58 -59 .............. Br ake [...]

197 Index M M aint enance Log 193- 195 ....... M aint enance Schedul e 94 - 96 ..... M aki ng T urns 79 .............. M anual S hif t 65 - 68 ............. Ma st er Cyli nder 58 - 59 .......... N Noi se Emi ssi on Cont rol 92 ...... O Oi l Change 107- 11 1 ............ Oil Filter Ch an ge 10 7 -111 ....... Oi l Level 105 - 106 .............. Oi l [...]