Polaris Outlaw 9922483 manual

This Category "S" (Sport) A TV is a high-per formance A TV for off-r oad use only . It is for sport-type recr eational and competitive use by operators with advanced skills and substantial experience. Operation is prohibited for anyone under 16 years of age. R ead this manual carefully . It contains important safety infor mation. 2010 Out[...]

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

The text is printed on 100% recycled with 40% po st-consumer wa ste (PCW).[...]

W ARNING Improper A TV use can result in SEVERE INJUR Y or DEA TH. READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS AND W ARNINGS. AL WA YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY P ASSENGERS NEVER USE WITH DRUGS OR ALCOHOL AL W A YS: use proper riding techniques to avoid vehicle overturns on hills and roug[...]

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

2 POLARIS, THE W A Y OUT and OUTL A W are registered trademarks of Polaris Industries Inc. Copyright 2009 Polaris Sales Inc. All in formation contained within this publication is based on the latest product information at the time of publicat ion. Due to constant improvements in th e design and quality of production components, some minor discrepan[...]

3 We l c om e Thank you for purcha sing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. W e proudly produce an exciti ng line of utility and recreational products. • Snowmobiles • All-terrain vehicles (A TVs) • RANGER ® utility vehicles • V ictory Motorcycles ®[...]

4 We lc o m e W e believe Polaris sets a standard of excellen ce for all utility and re creational vehicles man- ufactured in the world today . Many years of experience have gone into the eng ineering, design, and developm ent of your Polaris vehicl e, making it the finest ma chine we've ever produced . For safe and enj oyable operation of you[...]

5 T able of Content s Introduction . . . . . . . . . . . . . . . . . . 6 Safety . . . . . . . . . . . . . . . . . . . . . 10 F eatures and Controls . . . . . . . . 38 Operation . . . . . . . . . . . . . . . . . . 58 Emission Control S ystems . . . . . 83 Maintenance . . . . . . . . . . . . . . . . 85 Specifications . . . . . . . . . . . . . . 168 P[...]

6 Introduction Safety W ords and Symbols The following signal words and symbols appear through out this manual and on your vehicle. Y our safety is involved when these words and symbols are us ed. Become familiar with their meanings before r eading the manual. The safety ale rt symbol indicates a potential personal injury hazard. W ARNING A W ARNIN[...]

7 Introduction Failure to follow the warnings and safe ty precautions contained in this manual can result in severe injury or death. A Polaris A TV is not a toy and can be haza rdous to operate. This vehicle handles differently than other vehicles, su ch as motorcycles and cars. A collision or rollov e r can occ ur quickly , even during routine man[...]

8 Introduction Service Requirement s The high perform ance engine in your vehicle re q u i re s routine service to maintain the highest level of performance and reliability . Please read and follow the “B reak-In Period” and “Maintenance” sections of your Owner ’ s Manual carefully . Failure to perform the recom- mended procedures a t the[...]

9 Introduction V ehicle Identification Numbers V ehicle Model Number: __ _____________________________________________________ _____________ F rame V ehicle Identification Number ( 1): ______________________________ ________________________ Engine Serial Number (2): ________________________________ __________________________________ Key Number (on [...]

10 Safety Safety T raining A TV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding the A TV to take a training course. If you purchased a new Polaris A TV in the United S ta tes, your dealer provided instruction to you about the authorized A TV RiderCourse sm that is available to[...]

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

12 Safety Equipment Modifications W e are concerned for the safety of our custom ers and for the general public. Therefore, we strongly recommend that co nsumers do not inst all on a Polaris A TV any equipment that may increase the spe ed or power of the vehic le, or make any other modifications to the vehicle for these purposes. Any modifications [...]

13 Safety Safe Riding Gear Always wear clothing suited to the t ype of riding. A TV riding requires special protec tive clothing for comfort and to reduce the ch ance of injury . Helmet W earing a helmet can prevent a severe head injury . When- ever riding a Polaris vehicle, always wear a helmet tha t meets or exceeds establishe d safety standards.[...]

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

15 Safety Safety W arnings Failure to operate the A TV properly can result in a co llisi on, loss of control, a ccident or overturn, which may result in se rious injury or death. He ed all safe ty warnings outlined in this section of the owner ’s manual. See the OPERA TION section o f the ow ner ’s manual for proper operating procedures. Operat[...]

16 Safety Safety W arnings Operating Wit hout Instruction Operating this A TV without proper in struction increases the risk of an accident. The opera tor must unde rstand how to operate the A TV properly in different situations and on different types of terrain. Beginning and inexperie nced oper ators should co mplete the A TV RiderCourse sm offer[...]

17 Safety Safety W arnings Handling G asoline Gasoline is h ighly flammable and e xplosive under certain condi tions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • Do not smoke or allow open flames or sparks in or near the area where refuelin[...]

18 Safety Safety W arnings Failure to Inspect Before Operating Failure to inspect and verify that the A TV is in safe operating conditi on before operating increases the risk of an accident. Always inspect the A TV before each use to make sure it's in safe operating condition. Always fo llow all inspection and maintenance procedures and schedu[...]

19 Safety Safety W arnings Carrying a Passenger Carrying a passenger greatly reduces the operator's abil ity to balance and control the A TV , which may result in an accident or overturn. Never carry a passenger on thi s A TV . Using Alcohol or Drugs Operating the A TV after consuming alcohol or drugs could adve rsely affect operator judgme nt[...]

20 Safety Safety W arnings Operating on Pavement Operating an A TV on pa ved surfaces (including sidewalks, paths, parking lots and drivewa ys) may adversely affect the handling of the A TV and could result i n loss of control a nd accident or overturn. Avoid operating the A TV on p avement. A TV tir es are designed for of f-road use. If it's [...]

21 Safety Safety W arnings Operating at Excessiv e Speeds Operating the A TV at excessive speeds increases the operator's risk of losing control. Always operate at a speed that' s appropriate for the terrain, the visibility and operati ng conditions, and your expe rience. Physical Control of the A TV Removing a hand from the hand lebars o[...]

22 Safety Safety W arnings T urning Improperly T urning improperly co uld cause loss of traction, loss of control, accid ent or overturn. Always follow proper procedures for turning a s described in the owner's manual. Never turn abruptly or at sharp ang les. Never turn at high speeds. Practice tu rning at slow speeds before attempting to turn[...]

23 Safety Safety W arnings Improper Hill Clim bing Improper hill climbing c ould cause loss of control or overturn. Always follow prop er procedures for climbing hills a s described in the owner's manual. See page 72. Operating on S teep Hills Operating on excessivel y steep hills could cau se an overturn. Never operate on hil ls too steep for[...]

24 Safety Safety W arnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn. • Always follow proper procedures fo r traveling down hills as described in the owner's manual. NOTE: A special tech- nique is require d when braking while tra veling downhill. See pa ge 75. • Always descend a hill w[...]

25 Safety Safety W arnings Crossing Hillsides Driving on a sidehill is not recommended. Imprope r procedure could cause loss of control or overtu rn. Avoid crossing the side of any hill unless absolutely necessary . If crossing a hillside is unavoid able, always follow proper procedures as described in the owne r's manual. See page 74. Never a[...]

26 Safety Safety W arnings S talling While Climbing a Hill S talling, rolling backwards or improp erly dismounting while climb ing a hill could cau se an overturn. Always maintain a steady speed when climbing a hill. If all forward speed is lost Keep body weight uphill. Apply the front brakes graduall y (right lever). When fully stopped, apply th e[...]

27 Safety Safety W arnings Operating on Slippery T e rrain Failure to use extra caution when ope rating on excessively rough, slippery or loose terrain could cause loss of tracti on, loss of control, accid ent or overturn. Do not operate on excessively rough, slippe ry or loose terrain until you've learned and practiced the skills necessary to[...]

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

29 Safety Safety W arnings Improper V ehicle Modifications Improper installation of accessories or modification of the A TV may cause changes in handling, which co uld caus e loss of control or an accident. Never modify the A TV through improper installation or use of accessories. All part s an d accessories added to the vehicle mu st be genuine Po[...]

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

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

32 Safety Safety W arnings Operating on Frozen Bodies of W ater Operating on frozen bodies of water may resu lt in serious injury or death if the A TV and/or the operator fall through the ice. Never opera te the A TV on a frozen body of water . Operating a Damaged A TV Operating a da maged A TV can result in an accident. After any overturn or accid[...]

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

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

35 Safety Safety Labels and Locations General W arning W ARNING Improper A TV use can result in SEVERE INJURY OR DEA TH. Always use an approved helmet and protective gear . Never use on pu blic roads. Never carry passengers. Never use with drugs or alcohol. NEVER operate: • without proper training or instruction • at speeds too fast for your sk[...]

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

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

38 Features and Controls Start Butt on Engin e Stop Switch Main Key Switch[...]

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

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

41 Features and Con trols Light s Headlight s Use the headlight switch to turn the lights on and of f and to switch the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position to operate the headlights. Headlight Switch[...]

42 Features and Controls Clutch Lever The hydraulic clutch lever is located on the left handlebar . Squeeze the clutch lever toward the handlebar to dis engage the clutch. Disengage the clutch before shifting ge ars. The clutch is self-adjusting, but lever position can be changed to fit the operato r ’ s hand. T urn the adjusting knob countercloc[...]

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

44 Features and Controls Throttle Lever Operating an A TV with sticking or improperly operating throttl e controls could cause an accident. Never start or o perate an A TV that has a sticking or impr operly operating throttle. Always contact your dealer for service before operating th e vehicle. Failure to check or maintain proper operation of th e[...]

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

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

47 Features and Con trols Hand Brake The hand brake operates the front brakes. The hand brake is located on the right ha ndlebar . These brakes are hydraulically activated disc type brakes. Squeeze the brake lever toward the handlebar to engage the front brakes. Always test brake lever travel and master cylinder fluid level before riding. When sque[...]

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

49 Features and Con trols Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder be fore each ride. If the fluid level is low add DOT 4 brake fluid only . Do not overfill. S e e pa ge 170 for the part nu mbers of Polaris prod- ucts. Hand Brake Fluid Level 1. Position the A T V on a level surface. Position the handlebars so the m a[...]

50 Features and Controls Parking Brake 1. Place the transmission in fi rst gear . 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking bra ke lock inward to engage the lock. Release the brake lever . 4. T o rele ase the parking brake lock, squeeze and release the brake lever . The lock will automati-[...]

51 Features and Con trols Parking Brake The parking br ake may relax if left on for a lo ng period of time. Alway s block the wheels to prevent rolling. Always block th e wheels on the downhill side of the A TV if leaving it parked on a hill. Another option is to park t he A TV in a sidehill position. Never depend on the pa rking brake alone if the[...]

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

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

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

55 Features and Con trols Manual Shif t Deceleration T o slow or stop the ve hicle, release the thro ttle lever and apply the brakes smoothly and evenly . As the vehicle slows and engine RPM de creases, disengage the clutch and shift to a lower gear . Be sure the engine RPM has suffic iently decreased before shifting to a lower gear . W ARNING! Imp[...]

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

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

58 Operation Failure to operate the A TV properly can result in a co llisi on, loss of control, a ccident or overturn, which may result in se rious injury or death. Re ad and unde rstand all saf ety warning s outlined i n the safe ty section of this owner ’s manual. Break-In Period The break-in period for your new Polaris A TV is the first three [...]

59 Operation Break-In Period Perform the following break-in and maintenance procedures carefully . 1. Fill the fuel tank with gasoline. Always exercise extreme caution whenever han- dling gasoline. 2. Check the oil level. Add the recom- mended oil as needed to maintain the oil level in the pro per range. See page 97. 3. Allow the engine suf ficient[...]

60 Operation Pre-Ride Inspection Failure to inspect and verify that the A TV is in safe operating co ndition before operating increases the risk of an accident. Always inspect the A T V before each use to make sure it's in safe operating condition. Pre-Ride Check list P age Brake systems / lever travel En sure proper operation 46-51 144-145 Br[...]

61 Operation Pre-Ride Inspection Pre-Ride Check list P age Coolant (if applicab le) Ensure proper level 107 Coolant hoses (if ap plicable) Inspect for leaks -- Throttle Ensure smooth operation 44 Indicator lights / switches Ensure operation 40, 41 Engine stop switch Ensure proper ope ration 39 Air filter Inspect, clean, replace as ne eded 110 Air b[...]

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

63 Operation Safe Operation Practices 8. Drive in a mann er appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hand s from the han- dlebars wh ile operating, and always keep both feet on the footpeg s. 9. Never consum e alcohol or drugs before or[...]

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

65 Operation T rail Etiquette Always practice go od etiquette when riding. Allow a safe distance between your vehicle and other vehicles operatin g in the same area. Comm unic ate to oncoming operators by signaling the numb er of vehicles in your group. When stopping, move your v ehicle to the edge of the trail as far as possible to allow others to[...]

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

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

68 Operation Driving Procedure 1. W ear a helmet and eye protection. 2. Sit upright with both feet on the footpegs and both hands on th e handlebars. 3. S tart the engine and allow it to warm up. 4. Shift the transmission into gear . See page 52. 5. Check you r surroundings and determine your path of travel. 6. Release the parking brake. 7. Slowly [...]

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

70 Operation Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather , follow these precautions: 1. Slow down when entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can ca use skids. 3. Correct a skid by tu[...]

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

72 Operation Driving Uphill Braking and handling are greatly affected when operating in h illy terrain. Improper procedure could cause loss of control or overturn. Whenever tr aveling uphill, follow these precautions: 1. Drive straight uphill. 2. A void steep hills (25 ° maximum). 3. Always check the terrain carefully before ascending any hill. 4.[...]

73 Operation Driving Uphill 5. Keep both feet on the footp egs. 6. Shift body weight uph ill. 7. Proceed at a steady rate of speed and thro ttle opening. Openi ng the throttle suddenly could cause the A TV to flip over backwards. 8. Never back do wn a hill. W ARNING! Aggressive ly applying the foot brake when b acking down a hill may cause rear tip[...]

74 Operation Driving on a Sidehi ll (Sidehilling) Driving on a sideh ill is not recommende d. Improper proced ure could cause loss of control or overturn. A void crossing the side of any hill unless absolutely necessary . If crossing a sidehill is unavoidable , follow these precautions: 1. Slow down. 2. Lean into the hill, transferring your upper b[...]

75 Operation Driving Downhill Whenever descending a hill, follow these precautions: 1. A void steep hills (25 ° maximum). 2. Shift body weight uph ill. T ra nsfer your weight to the rear of the vehicle. 3. Drive straight downhill. 4. Slow down. Excessive speed when trav- eling downhill can cause loss of control. 5. Shift to the lowest gear possibl[...]

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

77 Operation T urning Around on a Hill 7. W ith the front brakes applied, pull in the clutch lever . Use the brakes to slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward. 8. W ith the fro nt brakes s till applied, release the clutch lever and lock the parking brake. Remount from the u[...]

78 Operation Parking on a Hill or Incline A void parking on a hill or incline if pos- sible. If it's unavoidable, follow these precautions: 1. T urn the engine off. 2. Place the transmission in fi rst gear . 3. Lock th e parking brake. 4. Always block the rear wheels o n the downhill side. See illustration. 5. T u rn the fuel valve of f.[...]

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

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

81 Operation Driving Through W ater NOTICE: Serious engine damage can result if the vehi cl e is not tho roughly inspected after operating in water deeper than the footpeg level. As s oon as possible, perform the inspections and maintenance services ou tlined in the p eriodic maintenance ch art beginning on p age 85. Engine oil and all grease fi tt[...]

82 Operation Driving in Reverse Follow these precautions w hen operating in reverse: 1. Always check for obstacles or peop le behind the vehicle. 2. Always avoid ba cking downhill. 3. Back slowly . 4. Apply the brakes lightly for stopping. 5. A void turning at sharp angles. 6. Never open the throttle suddenly while back- ing. Do not operate at full[...]

83 Emission Control Systems Noise Emission Control System Do not modify the engine, intak e or exhaust components, as doing so may affect compliance with U.S.A. EP A noise control requirements (40 CFR 205) and local noise level require- ments. Operation on Public Lands in the U.S.A. Y our Polaris vehicle has a spark arrestor that was tested and qua[...]

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

85 Maintena nce Periodic Maintenance Chart The high pe rformance engine in your vehic le re q u i re s routine service to maintain the highest level of performance and reliability . Please re ad and follow the “Break-In Period” and “Maintenance” sections of your Owner ’ s Manual carefully . Failure to perform the recomm ended maintenance [...]

86 Maintenance Periodic Maintenance Chart The recommended se rvice intervals are based on aver age riding conditions. V ehicles sub- jected to severe use must be inspected and serviced more frequently . Severe Use Definition • F requent immersi on in mud, water or sand • Racing or race-style high RPM use • Prolonged low sp eed, heavy load ope[...]

87 Maintena nce Periodic Maintenance Chart Improperly performing the pr ocedures marked with a Q coul d result in component fai lure and cause an accident, which may result in serious injury or death. Always have an authorized Pola ris dealer perform these services. Maintenance Chart Key X Perform these operations mo re often under severe use. E Em[...]

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

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

90 Maintenance Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks See Pag e Hours Calendar F uel Used in gallons (liters) Brake pad wear 10 Monthly -- Inspect regularly 145 Rear sprocket bolts 10 Monthly -- Check torque 149 Battery 10 Monthly -- Check terminals; clean; test 129 X E Air filter 15 Weekly -- Inspect;[...]

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

92 Maintenance Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) X z Upper steering post ( 1) 45 6 M -- Inspect; tighten fasteners; grease after washing A T V/driving in water X z F ront A-Arms (2) 45 6 M -- Inspect; tighten fasteners; grease (also after washing A T V[...]

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

94 Maintenance Periodic Maintenance Chart Item Maintenanc e Interval (whichever comes first) Remarks Hours Calendar F uel Used in gallons (liters) E Compression ring 90 -- 156 (600) See your dealer or refer to the Dealer Service Manual; measure ring gap a nd replace if at or below service limit E Oil scraper ring 90 -- 156 (6 00) Camshaft 90 -- 156[...]

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

96 Maintenance Engine Oil Recommendations Always check and change the en gine oil at the intervals outlin ed in the Peri odic Maintenance Chart beginning on page 85. Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W -50 4-cycle oil or a similar oil desi gne d for use in 4-stroke manual clutch A TV and motorcyc le app lication[...]

97 Maintena nce Engine Oil Level Check the oil level before each use of the vehicle. If the engine is cold, the oil level should be visible at the lower edge of the sight glass. If the engine is warm, the oil level should be visible at the center of the sight glass. A high oil level can cause engine overh e ating, which could result in en gine dama[...]

98 Maintenance Engine Oil Change Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Change the oil more frequen tly on vehicles subjected to severe use. IMPORT ANT : Perform the initial break-in oil change after the first three hours of operation. Always change both oil filters and clean t he oil[...]

99 Maintena nce Engine Oil Change 1. Position the vehicle on a level surface. 2. Remove the skid plate for better access to the oil drain pl ug and short screen. 3. S tart the engine. Allow it to idle for two t o three minutes. S top the engine. 4. Place a drain pan beneath the crankcase. Remove the drain plug. Allow the oil to drain completely . C[...]

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

101 Maintena nce Engine Oil Change Cleaning the Short Oil Screen 1. Remove the short oil screen plug at the bottom of the engine. See illustration on preceding pag e. 2. Remove the short oil screen from the plug. Cl ean the screen components thoroughly and blow well with compressed air . 3. Check the O-rings. If damaged, install new O-rings. 4. Rei[...]

102 Maintenance Engine Oil Change Cleaning the Long Oil Screen 1. Remove the long screen p lug, located on the side of the engine near the engine number . 2. Remove the oil scree n. Clean the screen thoroughly and blow wi th compressed air . 3. Check the O-rings. If d a maged, install new O-rings. 4. Place the long oil screen on a pin-type key or s[...]

103 Maintena nce Engine Oil Change Cleaning the Long Oil Screen 5. Insert the tool thro ugh the op ening and into the bo re of the opposite engine casing wall. Push the oil screen into the casing as far as possible. Remove the tool. NOTICE: An improperly installed oil screen will function poorly and result in incre ased engine wear . Install the sc[...]

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

105 Maintena nce Engine Oil Change Changing Oil Filters 6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. T ighten screws to 4.5 ft. lbs. (6 Nm). 8. Remove the oil fill plug (4). Add 1.7 qts. (1.6 l) of the recommended engine oil (see page 96). Reinstall the fill plug. 9. S tart the engine. Allow it to idle for at leas[...]

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

107 Maintena nce Engine Cooling System Coolant Level The reco very bottle is loca ted on the right side o f the vehicle under the front fender . If the fluid level is vis- ible at the bottom of the side panel, add 6 oz. (175 ml) of coolan t. As coolant operating te mperature increases , the expanding (heated) excess coolant is forced out of the rad[...]

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

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

110 Maintenance Air Filter Systems Refer to the illustrations on page 1 1 1. 1. Remove the seat. 2. Release the airbox cover clips and remove the cover . 3. Loosen the filter clamp. Remo ve the air filter from the box. 4. Locate the retaining spring. 5. Carefully remove the reta ining spring from the filter . 6. Remove the inner and ou ter foam fil[...]

111 Maintena nce Air Filter Systems Step 3 Step 5 Step 4 Step 7 Step 6[...]

112 Maintenance Carburetor Normal wear from engine vib rations may cause th e carburetor to supply an overly rich fuel mixture. Replace the jet needle and the need le jet after every 180 hours of operation. Idle S peed Carburetor idle adjustments affect engine starting behavior . A proper idle speed of 1500-1600 RPM will result in easier starting. [...]

113 Maintena nce Carburetor Carburetor Draining Drain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart be g inning on page 85. Al ways drain the bowl after exposure to wet conditions. Perform this procedure when the engine is cool. 1. T u rn the fuel valve of f. 2. Place a suitable container under the carburetor[...]

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

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

116 Maintenance Light s 4. Observe the headlight aim on the wall. The most intense part of the headlig ht beam should be aimed 2" (5 cm) below the mark placed on the wall. Include rider weight on the seat when measuring. 5. Loosen the pivot screw and adjust the beam to the desired position. 6. T ighten the screw and torque to 27 in. lbs. (3 Nm[...]

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

118 Maintenance Light s Headlight Assembly Replacement 1. Remove the front cover . 2. Remove the wire harness connector from the headlights. 3. Remove the two retaining brac kets and the adjuster screw . 4. Remove the headlamp. 5. Install the new headlamp, placing it in the sl ots on the fr ame tabs. Secure th e headlamp with the retaining brackets[...]

119 Maintena nce Light s Brake Light Adjustment Check the rear brake light for proper operation before each use of the vehicle. 1. T urn the ignition key on. 2. Lightly apply and release the foot brake several times. A properly operating rear brake light will immedi- ately flash on and off with each movement of the brake pedal. 3. If the light does[...]

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

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

122 Maintenance S park Plugs Refer to the specifications section beginning on page 168 for recommended spark plu g type and gap NOTICE: Using non-recommended spark plugs can result in serious engine damage. Alwa ys use Polaris-recomme nded spark plugs. Spark plug condition is indicativ e of engine operat ion. The spark plug firing end condition sh [...]

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

124 Maintenance S p ark Arrestor Clean-Ou t Failure to hee d the following warnin gs while servicing the spark arrestor could result i n serious injury or death. The exhau st system can get extremely hot. Do not perform service on the sp ark arrestor while the system is hot. Allow components to cool sufficiently before proceed ing. Remove any combu[...]

125 Maintena nce S p ark Arrestor Clean-Ou t T o remove ac cumulated carbon, clean the spark arrestor at the intervals recommended in the Peri- odic Maintenance Chart beginning on page 85. 1. Remove the retaining screw and remove the screen from the end of the m uffler . 2. Use a non-synthetic brush to clean the arres- tor screen. A synthetic brush[...]

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

127 Maintena nce V ehicle Immersion 1. T u rn the fuel valve of f. 2. Drain water from the air box and cl ean the air filter . See page 1 10. 3. Drain the carburetor bowl. See page 1 13. 4. Remove the spark plug. See page 122. W ARNING! Fluids wil l be ejected through the spark plug hole and may cause serious injury to face or other body part s. We[...]

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

129 Maintena nce Battery Improperly connecting or discon nec ting battery cables ca n result i n an explosion and cause serious injury or death. When removing the battery , always disconne ct the negative (black) ca ble first. When reinstalling the battery , always connect the negati ve (black) cable last. The seal ed battery is alread y filled wit[...]

130 Maintenance Batter y Stor age Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Battery Removal 1. Di[...]

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

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

133 Maintena nce Battery Charging (Sealed Battery) The Polaris Battery T ender batte ry char ger can be left connected duri ng the storage period and will automatically char ge the battery if th e voltage drops below a pre-determined point. If the battery fails to recharge d uring vehicle operation, check voltage regula tor connections. See your Po[...]

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

135 Maintena nce Ti r e s Operating your A TV with worn tires, imprope rly inflat ed tires, non-standard tires or improperly installed tires will affect vehicle handling and co uld cause an accident resultin g in serious injury or death . Always follow all tire maintenance proced ures as outlined in this manua l and on the labels on the vehicle. Al[...]

136 Maintenance Wheel Nut T o rque S pecifications Check the wheel nut torques occasionally and wh en they've been loo sened for maintenance. Wheel Hub Ti ghtening Front wheel bearing tightness an d spindle nut retention are cr itical componen t operations. All service must be performe d by your authorized Polaris dealer . Wheel Removal 1. S t[...]

137 Maintena nce Wheel Inst allation 1. Place the transmission in gear . Lock the parking brake. 2. Place the wheel on the wheel hub with the valve stem toward the outside and rotation arrow on the tire pointing toward forward rotation. 3. Install the wheel bolts and finger tighten them. 4. Lower the veh icle to the ground. 5. Securely tighten the [...]

138 Maintenance Boot Inspection Before Operating Inspect the b oots before operating the v ehicle. If a boot is torn, punctured or leaking flui d, see your Polaris dealer for service or replacement. Af ter Operating Inspect the boots after operating the vehicle. If a boot is bulging or balloo ned, perform the boot burping procedure on page 139. Goo[...]

139 Maintena nce Boot Burping 1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard bo ot. Do not use any t ools that may damage the boot. 2. Slide the free end of the bo ot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape (2). 3. W i[...]

140 Maintenance Clutch System Bleeding Always bleed the clutch system at the intervals out- lined in the Periodic Main tenance Chart beginnin g on page 85. Always bleed the clutch system any time the clutch lever feels unr esponsive. Always use the recommended fluid when bleeding the clutch system. See page 43. 1. Position the vehicle on a level su[...]

141 Maintena nce Clutch System Bleeding 4. Remove the bleeder screw (2) from the slave cylinde r . 5. Press fluid into the system unti l the fluid runs out of the hole (3) in the master cylinder without producing bubbles. TIP: Extract fluid fro m the master cylinder du ring the process to prevent overflowing. 6. When finished, remove the bleeder sy[...]

142 Maintenance Throttle Lever Freeplay Periodically check throttle lever freeplay . Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm). If adjustments are need ed, use the procedure on page 143. 1/16 " - 1/8" (1.5 - 3 mm)[...]

143 Maintena nce Throttle Cable Freeplay Adjustment Improper adjustment of throttle cab le freeplay can result in loss of control, which coul d result in serious injury or death. Polaris recommends that this proc edure be performed by a Polaris dealer to ensure that it's done correctly . Mechanically knowledge able persons who perfo rm this pr[...]

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

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

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

147 Maintena nce To e A l i g n m e n t 4. Measure the distance between the marks and record the measurement (1). 5. Move the vehicle until the chalk marks are at the rear of the tires, even with the hub/axle center line. 6. Measure the distance between the marks and record the measurement (2). 7. Subtract measurement 2 from measure- ment 1. The di[...]

148 Maintenance Chain T ension CAUTION! Never adjust or operate th e vehicle with the re ar d rive chain too loose or to o tight. Severe damage to the transmission and drive components can result. Check the amount of ch ain slack by moving the vehicle slightly forward to remove sl ack at the top side of the chain. At the center point of the top sid[...]

149 Maintena nce Chain T ension 3. T ighten the pivot mounting bolts to 30 ft. lbs. (40 Nm). 4. T orque the chain adjusting bolt to 17 ft. lbs. (23 Nm). 5. Check sprocket bo lts to make sure the retainer tabs fit tig htly against the bolt heads. If not, tighten the bolts t o 28 ft. lbs. (38 Nm). 6. Bend the retaining tabs tightly against the flat e[...]

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

151 Maintena nce S teering Inspection Check the steering assembly periodic ally for loos e nuts and bolts. If loose nuts and bolts are found, or if you notice any freeplay in the stee ring post, see your Polaris dealer for service before operating the vehi cle. Camber and Caster The camber and caster are non-adjustable.[...]

152 Maintenance Front Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. S top the engine. 3. Elevate the fron t of the vehicle by plac ing a suitable stand under the frame. The tires should be bare ly touching the grou nd and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of[...]

153 Maintena nce Front Suspension Suspension Set-Up 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the susp ension. 7. T urn the handleba rs fully to the left and right. 8. W ith the rider still on the vehicle, repeat the measu rement performed in step[...]

154 Maintenance Front Suspension S pring Preload The front suspension preload may be adjusted to suit different riding conditions and operator weight. W ARNING! Uneven adjustme nt may cause poor handling of the A TV , which could result in an accident and serious inj ury or death. Always ad just both the left and right spring preloads eq ually or h[...]

155 Maintena nce Front Suspension S pring Preload 1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully extend. 2. Loosen the jam nut. 3. T urn the adjustin g ring clockwise to inc rease preload. T urn the ring counter -cloc kwise to decrease preload. 4. T ighten the jam nut firm ly against the adjusti[...]

156 Maintenance Rear Suspension Suspension Set-Up 1. Position the vehicle on a level surface. 2. S top the engine. 3. Elevate the rear of the vehic le by placing a suitable stand under the frame. The tires should be bare ly touching the grou nd and the suspension should be at full rebound. 4. Measure the distance from the ground to the bottom of th[...]

157 Maintena nce Rear Suspension Suspension Set-Up 5. Remove the stand and have a rider sit comfor tably on the seat with hands on the handle- bars. 6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet (3 m) without lifting or pushing down on the susp ension. 7. T urn the handleba rs fully to the l[...]

158 Maintenance Rear Suspension The rear suspension spring preload and shock compression damping may be adjusted to su it dif ferent riding conditions and operator weight. S pring Preload 1. Raise and safely support the rear of the vehicle off the ground to allow the suspen sion to fully extend. 2. Loosen the jam nut. 3. T u rn the adjusting ring c[...]

159 Maintena nce Rear Suspension Compression Damping The comp ression damping clickers are located o n the bottom of the shocks (on the lower clevis). Use a screwdriver to make adjustments. T o se t the shock at the firmest setting, turn the screw clockwise until it stops (fully closed position). From this position, turn the sc rew counter -clockwi[...]

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

161 Maintena nce Cleaning W ashing the V ehicle W ashing Tips • A void the use of harsh cleane rs, which can scratch the finish. • Do not use a power washer to clean the vehicle. • Do not use medium to heavy duty compounds on the finish. • Always use clean cloths an d pads for cleaning and poli shing. Old or reused cloths an d pads may cont[...]

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

163 Maintena nce Polishing Polaris recommends the use of common household aerosol furniture po lish for polishing the finish on your Polaris vehicle. Fo llow t he instructions on the container . Polishing Tips • A void the use of automotive products, some of which can scratch the finish of your vehi- cle. • Always use clean cloths an d pads for[...]

164 Maintenance Sto r a ge Engine Oil Change the oil and both filters. Cl ean the oil screens. See page 98. Air Filter / Air Box Inspect and clean (or replace) the air filter . Clean the air box. Drai n the sediment tube. Fluid Levels Inspect fluid levels. Change fluids as reco mmended in the Period ic Maintenance Chart beginning o n page 85. • T[...]

165 Maintena nce Sto r a ge S ta bilize the Fuel 1. Fill the fuel tank with fuel. 2. Add Polaris Carbon Clean Fu el T reatmen t or Polaris Fuel S tabilizer . Follow the instruc- tions on the container for the recommended amount. Carb on Clean removes water from fuel systems, stabilizes fuel and removes car bon deposits f rom pistons, rings, valves [...]

166 Maintenance Sto r a ge Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main- tenance Chart beginning o n page 85. S torage Area/Covers 1. Make sure tire pressure is at specification. 2. Be sure the storage area is well ventilated. 3. Using suitable su pports under the frame, raise the vehicle s[...]

167 Maintena nce T ransporting the A TV Follow these procedures when transporting the vehicle. 1. S top the engine. 2. Place the transmission in first gear . 3. Lock th e parking brake. 4. Remove the key to preven t loss during transporting. 5. Secure the fuel cap, oil cap and seat. 6. T u rn the fuel valve of f. 7. Always tie the frame of the A TV[...]

168 S pecifications OUTL AW 525 IRS Max. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45 Dry Weight 389 lbs./176 kg Main Jet 148 F uel Capacity 3.1 gal./11.7 l Needle Jet OBDVS Overall Length 71.5 in./182 cm Needle Clip #4 Overall Width 47.5 in./121 cm Slow Air Jet 100 Overall Height 45 in./114 cm Alternator Output 200 w @ 3000 RPM Wheelbase 51 in./ [...]

169 S pecifications Jetting Chart OUTL AW 525 IRS Driving System T ype Rear T wo- Wheel Drive Tire Size - F ront 21 x 7R10 Shift T ype 5-Speed Manual Shift Tire Size - Rear 20 x 10R10 Primary Ratio 2.516 Tire Pressure - All 4 psi/27.6 KPa Gear Ratio - 1st 2.500 Front Br ake Hydraulic Disc, Dual Bore Gear Ratio - 2nd 1.941 Rear Brake Hydraulic Disc [...]

170 Polaris Product s P art Number Desc ription Engine L ubricant 2876244 PS-4 PLUS P erformance Synth etic 2W -50 4-Cycle Oil (qt.) 2876245 PS-4 PLUS P erformance Syn thetic 2W -50 4-Cycle Oil (gal.) Grease / Spec ialized Lubricants 2871312 Grease Gu n Kit, Premium All Season (3 oz.) 2871322 Premium All Season Grea se (3 oz. cartridge) 2871423 Pre[...]

171 Polaris Product s P art Number Descr iption Coolant 2871323 60/40 Coo lant (gal.) 2871534 60/40 Coo lant (qt.) Additives / Miscellaneo us 2871326 Carbon Clean Plus (12 oz.) 2870652 F uel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid (12 oz.) 2876335 Hydraul ic Clutch Oil (qt.)[...]

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

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

174 T roubleshooting Engine Doesn’t T urn Over Engine Pings or Knocks Possible Caus e Solution Fuseable link See Pol aris dealer for replacement Low battery voltage Rechar ge battery to 12.8 VDC Loose battery connections Chec k all connectio ns and tighten Loose solenoid connections Chec k all connectio ns and tighten Possible Caus e Solution Poo[...]

175 T r oubleshooting Engine Backfires Possible Caus e Solution W eak, fo uled or defective spark plug In spect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with new fuel Exhaust leak Inspect system for leaks; see your Polaris dealer Incorrectly instal[...]

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

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

178 T roubleshooting Engine Runs Irregularly , St alls or Misfires Possible Le an F uel Mixture Cause Solution Low or contaminated fuel Add or ch ange fuel, clean the fuel system Low octane fuel Replace with recommended fue l Old or non-recommended fuel Re place with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetti[...]

179 T r oubleshooting Engine Fails to Reach High RPM Engine Uses Excessive Oil Possible Caus e Solution W orn or dirty needle valve Clean and/or replace needle valve Loose carburetor jets T ighten jets Faulty ignition timing See your Polaris dealer Possible Caus e Solution Bent engine ventilatio n hose Install a new hose Excessive oil in syste m C [...]

180 T roubleshooting Engine S tops o r Loses Power Possible Caus e Solution Out of fuel T urn the fuel valve to reserve, ref uel Interrupted fuel supply Clean fuel system and carburetor Clogged, dirty or wet air filter I nspect and clean or replace Electronic throttle control ma lfunction See your Polaris dealer Other mechanical failure See your Po[...]

181 T r oubleshooting Engine S tops o r Loses Power Possible Caus e Solution Kinked or plugged fuel vent line Inspect and replace W ater present in fuel Replace with new fuel Overuse of choke Ins pect, cl ean a nd/or replace spark plugs Fouled or defective spark plug Inspec t, clean and/or replace spark plugs W orn or defective spark pl ug wire See[...]

182 T roubleshooting Engine Overheat s Possible Caus e Solution Debris lodged in screen Re move and clean the screen Plugged radiator Use a garden hose to flush any debris from the radia- tor fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling ef ficiency . Insufficient coolant Check levels a nd fill as needed; check f[...]

183 T r oubleshooting Engine Fails to Reach Full Powe r Possible Caus e Solution Interrupted fuel supply Clean fuel system and carburetor Float leak s Replace the float Clogged, dirty or wet air filter I nspect and clean or replace Faulty exhaust system Check system for damage; see your Polaris dealer V alve gap is too small Adjust valve gap Faulty[...]

184 Declaration of Conformity Polaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A. T elephone 763-542- 0500 W e, Polaris Industries Inc., declare that the vehicles lis ted be low conform to the e ssential health and safety requirements applicab le to off-road all-terrain vehicles. APPLICABLE EUROPEAN DIRECTIVES TEST / EV ALUA TION METHODS [...]

185 Declaration of Conformity PRODUCT IDENTIFICA TION VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___KA05__ OUTLA W 50 2008, 2009, 2010 76.8 ___KA09__ OUTLA W 90 2008, 2009, 2010 76.8 ___F A09__ SPOR TSMAN 90 2008, 2009, 201 0 76.8 ___V A17__ RZR 170 20 09, 2010 81.3 ___PB20__ PHOENIX 200 2008 , 2009, 2010 76.8 ___BA32__ TRAIL BLAZE[...]

186 Declaration of Conformity VEHICLE SERIES TRADE NAME MODEL YEARS SOUND PRESSURE dB (A) ___MN76__ SPOR TSMAN 800 2008, 2009, 2010 83.6 ___TN85__, ___ DN85__ SPOR TSMAN X2/TOURING 850 2010 77.2 ___CL76__ SPOR TSMAN 800 6X6 2009, 2010 80.1 ___ZN85__, ___ZX85__ SPOR TSMAN 850 EFI 2009, 2010 80.4 ___RH50__, ___ HH50__ R ANGER 500 EFI 4X4 2009, 2010 7[...]

187 W arranty LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED W ARRANTY on all components of t he Polaris All T errai n V ehicle (A TV) agai nst defects in material or wo rkmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warra nty cov[...]

188 Wa r r a n t y W A RRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES The Polaris l imited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accident al damage, normal wear and tear, a buse or improper ha ndling. Th is war- ranty also does not cover any[...]

189 W arranty W A RRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES W arranty applies to the product only and does not allow fo r coverage of personal loss. Some ite ms are considere d "consumable," meaning they are considered part of normal maintenance or part of completing an ef fective repair . The following ite[...]

190 Wa r r a n t y W A RRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES This warranty also excludes failures resulting from improper lubrication; im proper engine timing; improper fuel; surface imperfections caused by external stress, heat, col d or contamination; operator error or abuse; improper component a lignment, tens[...]

191 W arranty W A RRANTY COVERAGE AND EXCL USIONS: LIMIT A TIONS OF WARRANTIES AND REMEDIES ALL IMPLIED W ARRANTIE S (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE SIX MONTH W ARRANTY PERIOD. PO LARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES N[...]

192 Wa r r a n t y HOW TO OBT AIN W ARRANTY SERVICE If your A TV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris A TVs. When requesting warranty service you mu st present your copy of the W arranty Registration form to the dealer . (THE COST OF TRANSPOR T A TION T O AND FROM THE DEALER IS YOUR RESPONSIBI[...]

193 W arranty EXPORTED VEHICLES EXCEP T WHERE SPECIFICALL Y REQ UIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BUL- LETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COU NTR Y OF THE SELLING DEALER'S AUTHORIZED LO CA TION. This policy does not apply to vehicles that have received authorization for export from Po laris Industries. Dea[...]

194 Wa r r a n t y EXPORTED VEHICLES How to Get Ser vice I f Y ou Move: If you move to another country , be sure to contact Polaris Customer Assistance and the customs department of the destination country before you move. V ehicles importation rules vary considerably from country to country . Y ou may be required to present do cumentat ion of your[...]

195 W arranty U.S.A . EP A Emissions Limited W arranty This emissions limited warranty is in addition to the Pola ris standard limited warranty for y our vehicle. Polaris Industries Inc. warrants that at the tim e it is first purchased, this emis sions-c ertified vehicle is designed, built and equipped so it conforms with applic able U.S. Environme[...]

196 Wa r r a n t y U.S.A . EP A Emissions Limited W arranty For exhaust emissions , emission-relate d components in clude any engine pa rts related to the following systems: The following parts are also considered emission -related components fo r exhaust emissions: The following parts are considered emission -related components for evaporative emi[...]

197 W arranty U.S.A . EP A Emissions Limited W arranty The exclusive remedy for breach of this limited warranty shall be, at the exclusive opt ion of Polaris, repair or replacement of any defective materi als, components or products. THE REMEDIES SET FOR TH IN THIS LIM- ITED W ARRAN TY ARE THE ONL Y REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF [...]

198 Wa r r a n t y U.S.A . EP A Emissions Limited W arranty This limited war ranty excludes failures not caused by a defect in material or workmanship.This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limite d warranty also does not cover any engine that ha s been structural ly altere[...]

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

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

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

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

203 Index A Age Restrictions . . . . . . . . . . . . . . 15 Air Filter Systems . . . . . . . . . 110-111 B Battery Charging . . . . . . . . . . . . . 132-134 Installation . . . . . . . . . . . . . . . 131 Maintenance . . . . . . . . . . . . . 129 Removal . . . . . . . . . . . . . . . . . 130 Storage . . . . . . . . . . . . . . 1 30, 163 Bleeding th[...]

204 Index F Fluid Brake . . . . . . . . . . . . . . . . . . 48-49 Clutch . . . . . . . . . . . . . . . . . . . . 43 Foot Brake . . . . . . . . . . . . . . . . . . . 46 Foot Brake Flui d Level . . . . . . . . . 49 Fuel Filter . . . . . . . . . . . . . . . . . . . . 56 Fuel Safety . . . . . . . . . . . . . . . . . . . 17 Fuel Stabilizer . . . . . . .[...]

205 Index P Parking Brake . . . . . . . . . . . . . . 50-51 Parking on a Hill or In cline. . . . . . 78 Passenger Warnin g . . . . . . . . . . . . 37 Periodic Maintenance Ch art . . . 85-95 Polaris Products . . . . . . . . . . . . . 170 Polishing . . . . . . . . . . . . . . . . . . . 163 Pre-Ride Inspe ction . . . . . . . . . . 60- 61 R Restriction[...]

206 Index S Side Panel Remo val . . . . . . . . . . . 120 Sidehilling . . . . . . . . . . . . . . . . . . . 74 Signal words . . . . . . . . . . . . . . . . . . . 6 Spark Arrestor Clean-Out . . . 124-125 Spark Plugs . . . . . . . . . . . . . . 122-123 Spring Prelo ad . . . . . . . . . . . . . . . 154 Spring Prelo ad, Front . . . . . . . . . . 155 Sp[...]