Polaris Outlaw 9920783 manual

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

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2 POLARI S and POLARIS THE W A Y OUT a r e re gi s t e r e d tr a de ma r ks of Pol a ri s I ndus t r i e s I nc . Copyr ight 2006 Pola r is Sa le s I nc. All inf orm a t ion c onta ine d wi thin t his publi ca ti on is ba se d on the la te st produc t in form atio n at the time of pu b licatio n. Du e to con stant imp ro vem en ts in the desig n a[...]

3 WELC OM E Tha nk you for purcha sing a Polaris ve hicle, and w elc ome to our wor ld-wide family of Polaris ow ners. W e pr oudly produce a n exciting line of utility and r ecr ea tional products. S Snowmobiles S All- ter rain ve hicles (A TVs) S RANGER utility vehicle s S V ict or y mo to rcycl es[...]

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

5 TABL E OF CONTENT S KNOW YOUR VEHI CLE 6 ........................................... SAF ETY 8 ......................................................... FEA T URES AND CONTROLS 48 ..................................... OPE RA TION 67 .................................................... EMI SSION CO NTRO L SYST EMS 90 ..............................[...]

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

7 KNOW YOUR VE HICLE V ehicle I dentifica tion Num ber s V ehic le Model Number: Frame V IN ( 1)(lef t s ide): Engi ne Seria l Numbe r (2)(righ t side): Key Number ( 3): 2 1 31XX 3[...]

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

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

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

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

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

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

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

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

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

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

18 SA FE TY Operator S afety W ARNING Serious injury or deat h can res ult if you do not f ollow thes e inst ruct ions and procedur es, which are out lined in f urt her det ail within y our owner ’s manual. S Read t hi s m anual and al l l abel s careful ly , and f ollow the ope rating proc edures de - scr ibed. S Neve r opera te an A TV without [...]

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

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

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

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

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

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

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

26 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Failur e to f ollow t he age recom mendat ions f or t his A T V . WHA T CAN HAPPEN : Sev ere injury and/or death c ould occur if a c hild under t he minimum age rec ommendat ion operat es t his A T V . Even t hough a child m ay be wit hin the r ecomm ended age group f or operat ing som e A T[...]

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

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

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

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

31 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t he A T V af t er cons uming alcohol or drugs. WHA T CAN HAPPEN : Consum ption of alcohol and/ or dr ugs could s eriously affect operat or judgment . React ion tim e may be s lower and operat or balanc e and percept ion could be affec ted. Consum ing alcohol and/ or drugs befor e[...]

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

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

34 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Removing hands f rom t he handlebars or feet f rom t he foot pegs dur ing operat ion. WHA T CAN HAPPEN : Remov ing even one hand or f oot can reduc e ability to c ontr ol the v ehicle or c ould cause los s of balance and eject ion f rom t he A T V . If t he operat or ’s foot is not fir mly[...]

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

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

37 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : T urning im properly . WHA T CAN HAPPEN : I mproper tur ns could c ause loss of c ontr ol and lead to a collision or overt urn. HOW TO A VO ID THE HAZARD : A lways f ollow proper procedur es for t urning as descr ibed in the owner ’ s manual. Prac tic e tur ning at s low speeds bef ore at [...]

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

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

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

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

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

43 SA FE TY Operator S afety W ARNING POTENTI AL HAZARD : Oper ating t he A T V t hrough deep or fas t- flowing wat er . WHA T CAN HAPPEN : T ir es may f loat, caus ing loss of t ract ion and loss of cont rol, which could lead t o an acc ident or overt urn. HOW TO A VO ID THE HAZARD : Avoid operat ing t he A T V thr ough deep or fas t- flowing wat [...]

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

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

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

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

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

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

50 FEAT URES AND CONTROL S 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[...]

51 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 TV is not equipped with highway-appr oved light s. It ’s designed for and must be used f or of f -road use only . Use c aution and drive at reduc ed speeds in c ond[...]

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

53 FEAT URES AND CONTROL S Throttle Lever Ele ctroni c Throttle Control This A TV is equipped w ith Polaris Ele ctronic T hrottle Control (ETC) , which is de signed to re duce the r isk of a f roze n or stuc k throttle. I f the throttle c able should stic k in an open position when the opera tor rele ase s the throttle le ver , the engine w ill sto[...]

54 FEAT URES AND CONTROL S Foot Br ake The foot brake ( 1) operate s the re ar brake s. It’ s loca t ed in front of the right- hand footpeg (2). If the re ar wheels slide while using the foot brake, r educ e brak e pedal pres su re to brake the whee ls without skidding. Check the bra ke fluid l eve l fr equently for the foot brake system. The re [...]

55 FEAT URES AND CONTROL S Br ake L ever The bra ke lever oper ates the front brake s. It’ s loca t ed on the right 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 ev[...]

56 FEAT URES AND CONTROL S Master Cylinder The maste r cylinder (1) is on the right- hand handle bar . Check the bra ke fluid l eve l bef ore each rid e. T he flu id l evel can b e seen through thesight glass (2) on the side of the maste r cylinder . Mainta in the fluid le vel a t or slightly a bove the mark (3) ne ar the ce nter of the sight glass[...]

57 FEAT URES AND CONTROL S Master Cylinder W ARNING An over -f ull mast er c ylinder m ay caus e brake dr ag or brak e lock- up, whic h could result in ser ious injury or deat h. M aintain br ake f luid at t he rec ommended lev el. Do not overf ill. Af ter opening a bott le of brake f luid, always dis card any unused port ion. Never st ore or use a[...]

58 FEAT URES AND CONTROL S Park in g Bra k e W ARNING Oper ating t he A T V while t he park ing brake is engaged could r esult i n an accident and serious injur y or death. Always check to be s ure t he parking brake is disengaged bef ore operat ing. Lo cking th e Parkin g Brake 1. Place the tr ansmission in first gear . 2. S queeze an d rel ease t[...]

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

60 FEAT URES AND CONTROL S Fuel T ank The f uel tank fille r ca p is loc ate d directly be low the handle bar . Use either leade d or unlea ded gasoline with a minimum pump oc tane number of 87=(R+ M/2) octa ne. Do not use E-85 fuel. Fuel Fil ter The f uel valve ha s an inter nal fuel f ilter . Do not a ttempt to cle an the f uel filter . S ee your[...]

61 FEAT URES AND CONTROL S 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 thre e 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 exhausted. NOT E: T here’s about a 5 t o 8 mile ( 8 to 13 k m) r ange on reser ve gas. [...]

62 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 72 for corr ec t choke and throttle se ttings dur ing starting. 1[...]

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

64 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[...]

65 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 63. 2. Push the l ock- out leve r forw ard toward the handleba r to unlock the tra nsmission. 3. Shift down into reve r[...]

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

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

68 OPERATION Br eak - In Period Car eful tre atment of a ne w e ngine and tr ansmission w ill result in mor e ef fic ient per 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 io[...]

69 OPERATION Br eak - In Period 1. Fill the fuel tank with gasoline . See pa ge 60. 2. Check t he oil l evel on the dipst ick. S ee page 103. Add oi l if necessary to m aintain t he 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 [...]

70 OPERATION Pr e - Ride Insp ection W ARNING If a proper inspect ion is not done bef ore each us e, s evere injur y or death c ould result . Always inspect t he vehicle bef ore eac h use t o ensure it ’s in proper oper ating condit ion. Pre - Ri de Chec kl is t Item Remarks See Page Brake system / l ever tr avel Ensure proper oper ati on 55, 147[...]

71 OPERATION Pr e - Ride Insp ection Pre - Ri de Chec kl is t See Page Fram e nuts, bol ts, fast eners Inspect , ensure ti ghtness -- Fuel and oil Ensure proper l evels 103 Coolant l evel (i f applicabl e) Ensure proper l evel 11 2 Coolant hoses (i f appli cable) Inspect f or leaks -- Th ro ttle Ensure proper oper ati on 52, 164 Indi cator l ights [...]

72 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[...]

73 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[...]

74 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 63. 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[...]

75 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[...]

76 OPERATION Driving Safely Drivin g Procedures 1. Sit upright with both feet on the footpegs and both hands on the handleba rs. 2. Start the e ngine and allow it to war m up, then shift the transmission into gea r . S ee pa ge 64. 3. Check your surroundings and de t er mine your path of tra vel. 4. Relea se the parking brake . 5. Slowly depre ss t[...]

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

78 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[...]

79 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 ste ep 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 [...]

80 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[...]

81 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[...]

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

83 OPERATION Driving Safely T urning Around on a Hill 5. Staying uphill of the A TV , turn the handleba rs full left . Reach acro ss t he han dl ebar and app ly t he front br ake s to unlock the park ing bra ke. 6. W ith the front brake s applied, pull in the clutch leve r . Use the brakes to slowly allow the vehicle to roll a round to your r ight [...]

84 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void pa rking on an incline if possible. If it’ s unavoidable, fol lo w th ese p recaut ion s: 1. T urn the engine of f. 2. Place the tr ansmission in firs t gear . 3. Lock the parking bra ke. 4. Always block the rear whe els on t he downhill side. See illustra tion. 5. T urn the fuel[...]

85 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[...]

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

87 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[...]

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

89 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[...]

90 EMI SSION CONTROL SYST EMS Noise Em ission Control System Do not modify the engine , intake or exha ust compone nts, as doing so ma y af fec t complia nce with U.S.A. EP A noise control re quirements ( 40 C FR 205) and loca l noise leve l require ments. Operation on Public Land s in the U.S.A. Y ou r Po lari s veh icl e has a spark arrest or t h[...]

91 EMI SSION CONTROL SYST EMS Cr an kcase Em ission Control System This engine is equipped with a closed c rankca se system. Blow-by ga ses are force d back to the combustion cha mber by the intake system. All exha ust ga ses exit through the exhaust system. E xhaust E mi ssi on Contr ol Syst em The emissions fro m t he exha ust of this vehic le ar[...]

92 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[...]

93 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, hea vy load oper a- tion 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[...]

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

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

96 MAINT ENANCE AND LUBRICATION Per iod ic Maintenan ce Chart Item Maintenanc e Int erval (w hichev er c omes f irs t) Rem arks Hours Calendar Miles (Km) " Steer ing -- Pre- Ride -- C heck for f ree operation and loos e c ompo- nents " Air box sediment tubes -- Pre- Ride -- D rain depos its when v is ible Headlamp -- P re-R ide -- Chec k [...]

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) " 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[...]

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) Car buretor f loat bowl 50 H 6M 500 (800) Drain bow l periodic ally and prior to s tor age J E Thrott le Cable/E TC Switch 50 H 6M 500 (800) Ins pect ; adjust; r eplac e if neces s ary E Chok e (e[...]

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) " 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 driv ing in water " F Front A-Arm s (B) 50 H 3M 500 (800) I nspec t; t i[...]

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) Coolant s tr ength 50 H 6M 500 (800) I nspec t s tr ength s easonally ; pr ess ur e tes t s ys tem annually Co ol an t syste m p re ssur e te st 100 H 12 M 1000 (1600) Pr essu re te st system ann[...]

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

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

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

104 MAINT ENANCE AND LUBRICATION Engine Oil Level If the A TV is used ye ar -round, c hec k the oil le vel f re quently . A rising oil le vel could in di cate t he accu mu lat io n o f cont am in ates su ch as wat er o r excess fuel i n t he bo tt om of th e oil tank. W ate r in the bottom of the tank c an lea d to engine dama ge and must be d ra i[...]

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

106 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 drain pa n benea t h the oil tank a nd re move the[...]

107 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 drain c ompletely . 9. Replac e the se aling wa sher and r einstall the plug. T orque to 14 ft. l bs. (19 Nm). 10. Place shop towe ls be nea th the oil filter . 1 1. Remove the three c over bolts [...]

108 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 f acing outwa rd. 17. Install the c over a nd torque the bolts to 72- 78 in. lbs. (8-9 Nm). NOT E[...]

109 MAINT ENANCE AND LUBRICATION Oil an d F ilter Chang e 18. Remove the dipstick and f ill the oil tank with the rec ommended 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 10 . Then stop the engine and in sp ect for l eaks . 21. Re-che ck the oil le vel on the dip[...]

11 0 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[...]

111 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem The engine c oolant level is controlled or mainta ined by the recove ry system. The rec overy system compone nts a re the rec overy bottle, rad iator f iller ne ck, radia tor pressure c ap and conne cting hose. T o ensur e that the coolant mainta ins its a bility to prote ct the engine, we r[...]

11 2 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem Co olant L evel 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 m ust 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 ncr[...]

11 3 MAINT ENANCE AND LUBRICATION E ngine C ooling S ystem W ARNING Esc aping st eam can c ause sev ere burns . Nev er rem ove t he press ure cap while t he engine is warm or hot . A lways allow t he engine t o cool bef ore rem oving t he cap. Rad iato r Coo lant Level This proce dure is re quired only if the c ooling system has bee n dra ined for [...]

11 4 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 clamp ( 3). 5. Remove the ma in a ir filter (4) . 6. Remove the p re -filter ( 5) from the main f[...]

11 5 MAINT ENANCE AND LUBRICATION Air Filter System s 9. W ash the ma i n f ilter e leme nt (4) w ithout re moving it from the interna l filter cage . Rinse and l et dry . 10. Apply a commer cially av aila ble foam filte r lubric ant to the foam filte r . 1 1. Reinstall a ll components. 12 . C heck t he hoses for cracks, d eteri orat i on, ab rasi [...]

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

11 7 MAINT ENANCE AND LUBRICATION Lights Head light L amp Rep lacement 1. Remove the wir e harness conne ctor from the bac k of the he adlight. 2. On the 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[...]

11 8 MAINT ENANCE AND LUBRICATION Lights Head light A ssembly Replacem ent 1. Remove the wir e harness conne ctor from the headlights. 2. Remove the fr ont cab (see pa ge 121). 3. R em ove th e smal l adj ust er bracket (1 ). Ins tal l it o n th e new lam p. 4. Remove the lar ge pivot brac ket (2) and remove the he adlamp. 5. Insta l l the ne w hea[...]

11 9 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 s[...]

120 MAINT ENANCE AND LUBRICATION Lights Brak e Li ght Adjustme nt Ch eck t he rear b rake l ig ht for pro per o perat ion befo re each us e of the vehic le. 1. T urn the ignition key on. 2. Lightly apply and rele ase the foot brake se vera l times. A prope rly opera ting rear brake light will immediately f lash on and off with each m ov emen t of t[...]

121 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. Remove the fue l tank cove r scre ws (2). 4. Remove the four side pa nel s cr ews (3). 5. Gently pull the c ab upward to dis[...]

122 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 c ab. 3. Remove the ca b. 3 2 1[...]

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

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

125 MAINT ENANCE AND LUBRICATION S par k Plugs Spark Plug R emoval and R eplacement 1. Remove the side pane l s and front cab (se e page 121). 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[...]

126 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[...]

127 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 t ank r ea rwar d and upward ove r the engine. Slowly remove the tank and 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[...]

128 MAINT ENANCE AND LUBRICATION Spar k Arr esto r Clean - Out W ARNING Do not per for m clean- out im mediat ely af ter the engine has been run, as t he exhaus t system becomes very hot . Seri ous burns could result f ro m contact wit h the exhaust component s. Wear eye prot ect ion and gloves . Never r un the engine in an enc losed area. Ex haust[...]

129 MAINT ENANCE AND LUBRICATION Spar k Arr esto r Clean - Out Peri odical ly cl ean the spark arres tor to rem ove accumul ated carbon. Y our vehicl e has ei ther an end ca p-type arr estor or a set scr ew- type arr estor . P er form the appropria te clean- out proce dure for your ar restor type. End C ap - T yp e Arrest or 1. Remove the three sc [...]

130 MAINT ENANCE AND LUBRICATION Spar k Arr esto r Clean - Out Set Screw- T ype Ar resto r 1. Remove the bolt (1) and re move the arr estor (2) fr om the end of the muf fler . 2. Use a non-synthe tic brush t o cle an the ar re stor scr een (3 ). A synthe tic brush may me lt if c omponents are warm. If n ecess ary , bl ow deb ris from th e screen wi[...]

131 MAINT ENANCE AND LUBRICATION V eh i cl e Imme rs io n If your A TV has be en subme rge d or overtur ned in wa t er deepe r than the f ootpeg le vel, it’ s cr itical to dry it pro mptly and pr operly be fore sta rting the engine . CAUTION Do not s tar t t he engine af ter an A T V has been in wat er t hat exceeds the recom mended dept h. S eri[...]

132 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 14. 3. Drain the fuel/wa t er f rom the carbur etor for about 10 sec onds. 4. Remove the spar k plug. See page 125. W ARNING Fluids will be eject ed thr ough the s park plu[...]

133 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[...]

134 MAINT ENANCE AND LUBRICATION Batter y The seale d batter y is alre ady fille d with ele ctrolyte and ha s been se aled a nd fully char ged at th e facto ry . N ever pry the se aling strip of f or add any othe r fluid to this batte ry . Keep bat tery t ermi nal s and con nect io ns free of corros io n. If clean ing i s neces sary , remo ve the c[...]

135 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 121) a nd disc onnect [...]

136 MAINT ENANCE AND LUBRICATION Battery Installation 1. Plac e the batte ry in the batte ry holder . 2. Connec t and tighten the red (positive ) ca ble first, then c onnect a nd tighten the black (neg ati ve) cabl e. 3. Attac h the hold-down stra p and re install the f ront ca b. 4. V er i fy tha t cables a re prope rly routed. NOT E: W hen inst a[...]

137 MAINT ENANCE AND LUBRICATION Batter y Charging (S ealed Batter y) The ba ttery include d with your A TV is sea led and the se aling strip c annot be r emoved. Use a voltme ter or multime ter to mea sure D C voltage . A fully c har ged ba ttery w ill re gister 12. 8 V or higher . If the voltage is less than 12.8 volts, rec har ge the batter y . [...]

138 MAINT ENANCE AND LUBRICATION Batter y Charging (S ealed Batter y) Whe n using an automa tic cha r ger suc h as the Polar i s Batte ry T ender t , refer t o t he manuf ac t ure r ’ s instructions for r echar ging. Whe n using a constant curr ent char ger , use t he guideline s on the following page for r echar ging. W ARNING An over heated bat[...]

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

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 r ead Depth Always re place tires when tr ea d depth is wor n to 1/8 ″ (3 mm) or less. Se e illustration. Wheel Rem o val 1. Stop the engine, place the tr ansmission in gear a nd lo ck th e parki ng brak e. 2. Loosen the whe el nuts slightly . 3. Eleva te the side of the vehicle by plac ing a suita ble sta[...]

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 o rque 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 ″ 30- 35 ft . lbs. (40-47 Nm ) Rear 3/8 ″ 30- 35 ft . lbs. (40-47 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 ba llooned, per [...]

145 MAINT ENANCE AND LUBRICATION Boot B urping 1. Using a needle nose plie rs or boot cla mp removal tool, remove the small boot c l amp ( 1) fro m 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 [...]

146 ADJUST MENTS Br akes Under normal oper ation, the dia phra gm exte nds into the re servoir as fluid le vel drops. If the f luid leve l is low and the diaphrag m is not extende d, a lea k is likely and the dia phragm should be replaced. Always fill the reservoi r as needed when ever the cover is loosened or re moved to ensure pr oper dia phragm [...]

147 ADJUST MENTS Br akes 1. Always ke ep brake fluid at an a dequate level. See page 56. 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. Ins pect th e r[...]

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 Ali gnment 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 Ali gnment 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 en sion CAUTION Never adjus t or operat e the v ehicle wit h the r ear driv e chain t oo loose or t oo t ight. Sever e damage t o the t rans miss ion and drive c omponent s can r esult . Chec k the amount of c hain sla ck by moving the ve hicle slightly forwa rd to re move sla ck a t the top side of the chain. At the cente [...]

151 ADJUST MENTS Chain T en sion 1. Loosen the upper and lowe r 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 or que the cha in adjusting bolt to 17 ft. lbs. (23 Nm). Proper Spl iceli nk 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 che cked pe riodically f or loose nuts and bolts. If loose nuts and bolts ar e found, or if you notice any f ree play in 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 n[...]

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 transmission in ne utral and slowly ro ll the mac hine forwa rd and re arwar d at lea st ten f ee t (3 m) without lifting or pushing down on the suspension. 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 men[...]

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

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 fully e xtend. 2. T urn the adjusting r ing (1) cloc kwise to in crease prel oad (A). T u rn t he ri ng counte r- clockwise to dec rea se pre load (B). A B 1[...]

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 and ha ve a r ider sit comf ortably on the se at with hands on the handle bars. 6. Place the transmission in ne utral and slowly ro ll the mac hine forwa rd and re arwar d at lea st ten f ee t (3 m) without lifting or pushing down on the suspension. 7. T urn the ha ndlebar s[...]

160 ADJUST MENTS Rear S uspen sion Whe n the adjuste r sc re w is turned c ounter -cloc kwise until it stops, the damping is in the softest position ( position #1). T urn the scr ew cloc kwise to incr ease d amping. NOT E: Us e a flat blade sc rewdriv er t o make dam ping adjust ment s. Rear Sh ock Se ttin g Compr ession Dampi ng So fte st Positi o[...]

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 weight. 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. T urn the adj[...]

1 162 ADJUST MENTS Rear S uspen sion Co mpression D amping The c ompression damping c lickers ( 1) are locate d on the bottom of t he shocks (on the lower c levis) . Use a scr ewdriver to make adjustme nts. T o set the shock at the softe st setting ( position #1) turn the scr ew counte r -clock wise until it stops. From this position, turn the scre[...]

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

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 arm up the engine by running the vehicle f or five minute s, or u nt il operat i ng t emp eratu re is reached . 2. Apply the parking bra ke and place the tra nsmission in neutr[...]

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 and/or temper ature cha nges. If the veh icle is to be opera ted at various altitude s a nd te mperatur es, certa in adjustme nts can be ma de to improve its operation a nd drivea bility . Above 6000 feet ( 1800 m) the engine a i r/f [...]

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

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

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

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

171 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 t he engine during t he st orage period. Clean t he Exterio r Make a ny ne cessa ry repair s a nd clea n the ve hicle as re comme nded. S[...]

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

173 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[...]

174 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[...]

175 CLEANING AND ST ORAGE T r ansporti ng the A TV Follow these pr ocedure s when transpor ting the vehic l e. 1. T urn 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 n[...]

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

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

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

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

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

181 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[...]

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

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

184 SPECIF ICATIO NS OUTLA W Gro ss V eh icle W e igh 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 Jet N eedle 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 p[...]

185 SPECIF ICATIO NS OUTLA W Driv ing Sy stem T y pe Rear T wo - Wheel Dri v e T ire Size/Pressure - F ron t 2 1x7 R 1 0/5p s i S hif t T ype 5 - Speed Manual S hift T ir e Size/ Press u re - R ear 2 0x1 0 R 9/5p s i Prima ry Ra tio 2. 880 F ront B rake Hydraulic Disc Gear Rat io - 1st 2.429 R ear Brake Hydrau lic Di sc Gear Rati o - 2nd 1.61 1 Par[...]

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

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

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

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

190 WARRANTY Exported V ehicles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE I F IT I S SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORI ZED LOCA TI ON. Th is po licy d o es n o t app ly to v ehicles th at h av e receiv ed au th o rization fo r e xpor t fr om Pola ri[...]

191 WARRANTY Exported V ehicles How to G et S erv ic e In th e C o un try w h ere you r veh icle w as p u rch a sed: W a rr ant y or Se rvi ce Bull et in r epa ir s m ust be done by an a uthor iz ed Pol ar is de al er . If you move or a re tr ave li ng wi thi n the c ountr y wher e your vehi cl e w as purc has ed, W a rr ant y or Se rvi ce Bull et [...]

192 WARRANTY Exported V ehicles How to G et S erv ic e If P urch a sed Fro m A P rivate P a rty: I f you pur c ha se a Pol ar is pr oduct f r om a pri vat e ci ti ze n outs ide of t he count ry in whic h the ve hic le wa s ori gina ll y pur c has ed, a ll wa rr ant y cove ra ge wil l be deni ed. Notic e I f your vehi cl e is r egi st er ed outs ide[...]

193 WARRANTY U. S.A. EP A Emi ss i on s L i mit e d W a rran t y Th is All T errain V ehicle (A T V) or Off R oad U tility V ehicle (ORU V ) em ission s limited warran ty is in add itio n to th e P o laris stan d ard limited w arran ty for this veh icle. Po laris w arran ts th at this v eh icle is; (1 ) d esig ned , b u ilt, an d eq u ip ped to co [...]

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

195 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.[...]

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

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

198 INDEX A Ag e Res trictio n s 14 ............ Air Filter Sy ste ms 114 - 11 5 ....... B Batte ry 13 4 .................. Bat tery C har ging, Seal ed Batt ery 137 - 139 ..... Batte ry In stalla tion 13 6 ......... Bat tery R emoval 135 ........... Bat ter y S tor age 135 ............ Boo t Burp ing 14 5 ............. Boo t In spe ctio n 14 4 ...[...]

199 INDEX L Li ght Swi tches 51 ............. Li ghts 51, 1 16 - 120 ............. Lubr icati on Recommendat ions 102 M M aint enance Chart 95 - 101 ....... M aint enance Log 196 - 197 ....... Ma int enance Record 195 ........ M aint enance Schedul e 92 -94 ..... M aki ng T urns 77 .............. M anual S hif t 63 - 66 ............. Ma st er Cyli [...]