Polaris PTV 4x4 Series 10, Owner'S Manual

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Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

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Page 4: ...ing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A ...

Page 5: ...cle making it the finest vehicle we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technici...

Page 6: ... stolen these numbers are essential to its recovery and identification Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided 2 1 31XX 3 Frame VIN Engi...

Page 7: ...38 FEATURES 48 OPERATION 51 NOISE EMISSION CONTROL SYSTEM REGULATION 69 MAINTENANCE AND LUBRICATION 70 SPECIFICATIONS 112 POLARIS RECOMMENDED PRODUCTS 115 TROUBLESHOOTING 116 WARRANTY 120 INDEX 123 NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 8: ...hicle are thoroughly inspected at specific intervals Safety Training When you purchased your new PTV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used Polaris PTV from a party other than a Po...

Page 9: ...on your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION NOTE A note will alert you to important information or instructions A caution indicates a sit...

Page 10: ...g an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other s...

Page 11: ...follow proper procedures for crossing the side of a hill Avoid hills with excessively slippery or loose surfaces Shift your weight to the uphill side of the vehicle Never attempt to turn the vehicle around on any hill until you ve mastered on level ground the turning technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use proper procedures if the vehicl...

Page 12: ...r your vehicle and always maintain proper tire pressure S Never modify this vehicle through improper installation or use of accessories S Never exceed the stated load capacity for your vehicle Cargo must be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or towing Allow a greater distance for braking S Always remove the ignition ...

Page 13: ...ain accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle WARNING Make sure your PTV is in excellent operating condition at all times We strongly recommend that the operator check all safety components bef...

Page 14: ...e and the operating techniques described in the owner s manual For more information about the training course contact an authorized Polaris dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to follow the age recommendations for this vehicle WHAT CAN HAPPEN Severe injury and or death could occur if a person under the age of 16 operates a PTV Even though a child may be within the rec...

Page 15: ...es the operator s ability to balance and control the vehicle which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING ...

Page 16: ...ways WHAT CAN HAPPEN PTV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the vehicle and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the vehicle on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING ...

Page 17: ...erating this vehicle on public streets roads or highways WHAT CAN HAPPEN The vehicle could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the vehicle on any public street road or highway including dirt and gravel roads WARNING ...

Page 18: ... increases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident HOW TO AVOID THE HAZARD Always wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants ...

Page 19: ...icle could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating this vehicle POTENTIAL HAZARD Operating the vehicle at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the vehicle which can result in an accident causing severe injury or death HOW TO AVOID THE HAZARD...

Page 20: ...ARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt wheelies jumps or other stunts Avoid exhibition driving WARNING ...

Page 21: ...procedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the vehicle If the operator s foot is not firmly planted on the footrest it could come into contact with the ...

Page 22: ...cle on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions WARNING ...

Page 23: ... rough slippery or loose terrain could cause loss of traction or loss of control which could result in an accident or overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the vehicle on such terrain Always use extra caution on rough slippery or loose terrain WARNING ...

Page 24: ...in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the vehicle or for your abilities Never operate the vehicle on hills steeper than 25_ Practice on smaller hills befor...

Page 25: ...s described in the owner s manual Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill The vehicle could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the other...

Page 26: ...or traveling down hills as described in the owner s manual A special technique is required when braking while traveling downhill See page 62 Always check the terrain carefully before descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when ...

Page 27: ...he vehicle around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 63 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to the...

Page 28: ...s Lock the parking brake when fully stopped If the vehicle begins rolling backwards Keep your weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the rear brake as well and then lock the parking brake Dismount on uphill side or to either side if the vehicle is pointed straight uphill Turn the vehi...

Page 29: ...erating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme caution POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the vehicle could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra caution to reduce the chance of skiddi...

Page 30: ...ight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The vehicle could ...

Page 31: ...n the owner s manual POTENTIAL HAZARD Operating the vehicle with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the vehicle may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the vehicle through improper installation or use of accessories All parts and accessories added to the vehicle must be genuine Po...

Page 32: ...le Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 57 POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the vehicle and or the operator fall...

Page 33: ...sons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire WARNING WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in...

Page 34: ...LER FOR A REPLACEMENT WARNING This vehicle is equipped with a back up alarm ALARM MUST SOUND when operating this vehicle in reverse Failure to maintain a clear view in the direction of travel could result in serious injury or death The Operator is responsible for the safe operation of this vehicle 7170572 DNever operate this vehicle on HILLS steeper than 25 degrees 25 DUse OVERRIDE for reverse spe...

Page 35: ...secured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks with dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for more detailed loading information WA...

Page 36: ...gine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7078689 S Specific carburetor jetting and adjustments are required depending on temperature and altitude See your owner s manual Factory setting 40_ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters 7079901 WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle d...

Page 37: ... owner s manual OVERRIDE SWITCH 7079906 7078261 TRAILER MAX WEIGHT 1225 LBS 557 KG ON LEVEL GROUND 850 LBS 368 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 35 LBS 16KG Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 60 Ft Lbs For models with a hitch 7078572 WARNING Pushing reverse ...

Page 38: ...nk Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Gaso line powered engine exhaust fumes are poisonous and can cause loss of consciousness and death in a short time S Turn the fuel valve off whenever the vehicle is stored or parked The engine exhaust f...

Page 39: ...f Transportation DOT label the American National Standards Institute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Gloves with knuckle p...

Page 40: ...provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch will shut off electrical power to the entire vehicle including lights To stop the engine slide the stop switch either right or left to the OFF position Horn Switch 3 Main Switch 4 To start the engine slide the stop switch to the cent...

Page 41: ...the key off to prevent battery drain Light Switches The light switch is located on the left handlebar It s used to turn the lights on and off and to switch the lights from HI to LO on models equipped with HI LO beams NOTE The lights won t work unless the key is in the on position and the shut off switch is in the run position 1 2 3 Operating the vehicle on streets or roads especially in darkness c...

Page 42: ...ops the engine in the event of a throttle system malfunction and is provided for your safety Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms WARNING Operating a PTV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death Never start or operate a PTV with a sticking or improperly operating thr...

Page 43: ...inder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 1 Operating the vehicle with a spongy brake lever can result in loss of brakes which could cause an accident and lead to serious injury or death Neve...

Page 44: ...e will be clear NOTE When checking the fluid level the vehicle must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid see page 115 1 2 After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling tem...

Page 45: ...eels without skidding Brake Fluid Level Check the brake fluid level frequently for the auxiliary brake system The reservoir is located inside the right hand rear fender 2 Maintain the fluid level between the maximum and minimum marks Aggressively applying the rear brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxil...

Page 46: ... relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the vehicle if leav ing it parked on a hill Another option is to park the vehicle in a sidehill position S Never depend on the parking brake alone for more than five minutes if the vehicle is parked on a hill Always block the wheels to pre vent rolling Operating...

Page 47: ...ve supply if main supply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to the ON position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M ...

Page 48: ...ked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life refrain from continuous operation of the vehicle at the point of engagement the point at which the vehicle begins to move Continuous operation in this manner increases belt wear F N...

Page 49: ...t and restores compression for operation 1 Position the vehicle on a level surface and engage the parking brake See page 44 2 Shift the transmission to neutral 3 Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine 1 Extending the starter rope too far will cause damage to the recoil assembly Do not extend th...

Page 50: ...nal features available through a sub menu S Programmable service reminder based on hours S Programmable service reminder based on distance S Change measurement from miles to kilometers or vice versa Each service reminder is set to zero and must be programmed to activate the feature One or both service reminders can be set Whichever setting is reached first the reminder light will display in the LC...

Page 51: ...asurement is kilometers if the last digit is M distance is being measured in miles Set Service Hours 1 Access the sub menu 2 Toggle to SET hr then release the button 3 In 3 seconds the LCD will display 5 digits with the left most digit flashing 4 Within 4 seconds press and release the button to change the digit Once the digit is changed the button may be held to scroll through the digits from 0 to...

Page 52: ...ither turn the power off or not touch the button for 35 seconds to maintain the current settings Set Service Distance The procedure for setting Service Distance is the same as for setting Service Hours but toggle to SET dIS instead of SET hr Check When Service is Due by Distance The procedure for checking Service Distance is the same as for checking Service Hours but toggle to SET dIS instead of S...

Page 53: ...Polaris recommended products 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 52 6 Pull only light loads during the break in period 7 During the...

Page 54: ... stop switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element check for dirt clean or replace 9 Steering check for free operation noting any unusual looseness in any area 10 Loose parts visually inspect vehicle for any damaged components or loose nuts bolts or fasteners 11 Riding gear wear a hel...

Page 55: ...ter Activate the starter for a maximum of five seconds releasing the switch when the vehicle starts If the engine does not start release the starter and wait five seconds Activate the starter for another five seconds if necessary Repeat this procedure until the engine starts 7 If the engine slows or stops position the choke knob half way in to allow proper engine warm up 8 Vary the engine RPM slig...

Page 56: ...ne is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Cold Weather Operation If the PTV is used year round check the oil level frequently A rising oil level could indicate the accumulation of cont...

Page 57: ...t to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 58: ...the vehicle S CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Car rying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition When car go loads are carried high on the racks the weight of the loads must be reduced to maintain stable operating conditions S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that...

Page 59: ...ont Rack Cargo Rear Rack Cargo PTV 4x4 800 lbs 397 kg 90 lbs 45 kg 180 lbs 90 kg Improper loading of the front rack can obstruct the headlight beam reducing night visibility Do not obstruct the headlight beam Maximum Towing Capacities Level Ground Maximum trailer weight 1225 lbs 608 kg maximum vertical hitch weight 35 lbs 17 kg NOTE The rear rack capacity and tongue weight should not exceed 180 lb...

Page 60: ...e tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse WARNING Turning at sharp angles or at excessive ...

Page 61: ...e trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excess...

Page 62: ...hrottle opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 25_ Maximum WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 25_ maximum Use extreme caution when operating on hills and ...

Page 63: ...ht toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the ...

Page 64: ...weight to the rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with operation of the auxiliary rear brake pedal in the event loss of normal service brakes occurs Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 65: ...g the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the ser...

Page 66: ... and rear gearcases and all grease fittings NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully avoid sudden movements and maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes If your vehicle becomes immersed and...

Page 67: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain WARNING ...

Page 68: ...creased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle ...

Page 69: ...d parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 1 Place the transmission in gear 2 Set the parking brake 3 Always block the rear wheels on the downhill side See illustration 4 Shut off the fuel supply ...

Page 70: ...68 NOTES ...

Page 71: ...NG ARE THE ACTS LISTED BELOW INCLUDE BUT ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component that conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper main...

Page 72: ...average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your Polaris dealer NOTE Servi...

Page 73: ...re Ride Pre Ride Replace coolant every two years Fuel and oil tanks Pre Ride Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine stop switch Pre Ride Pre Ride Check operation Steering Pre Ride Pre Ride Check for free operation Air box sediment tube Pre Ride Pre Ride Drain deposits whenever visible Headlamp Pre Ride Pre Ride Chec...

Page 74: ...ically Front and rear gearcase oil shaft drive 100 hrs Monthly Check monthly change annually Engine cylinder head and cylinder base fasteners 25 hrs 3 months Inspect re torque required at first service only General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc L Engine oil level oil change 100 hrs 1000 miles 6 months Check level daily break in service at one month change oil...

Page 75: ...d check 50 hrs 6 months Check monthly Shift linkage 50 hrs 6 months Inspect adjust J Drive belt 50 hrs 6 months Inspect replace as needed Steering 50 hrs 6 months Inspect daily lubricate Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear suspension 50 hrs 6 months Inspect tighten fasteners L Spark plug 100 hrs 12 months Inspect replace as needed Rear axle 50 hrs 6 months Ins...

Page 76: ... selector box 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change every two years L Idle speed As required Adjust Recoil housing As required Drain moisture out after rid ing in water J Toe adjustment As required Periodic inspection adjust when parts are replaced Headlight aim As required Adjust as needed More often under severe use such as dirty or wet conditi...

Page 77: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 78: ...re washing or submerging When suspension action becomes stiff or after washing Item Lube Method Frequency Engine OIl Polaris Premium 4 Synthetic 0W 40 Add to proper level on dip stick See page 78 Check level daily Brake Fluid DOT 3 Only See page 42 As required change every two years or 200 hours 1 Transmis sion Oil Polaris Premium Synthetic gear case lube See Page 81 Change annually or at 100 hour...

Page 79: ...einstall set screw Annually or at 100 hrs 6 Ball Joint LGrease Locate fitting on back side of struts and grease with grease gun Every 3 months or 50 hours 7 Front A Arm Pivot Shaft LGrease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 8 Upper steering Post Bushing LGrease Locate fitting on steering post and grease with grease gun Every 3 months or 50 hours 8 6...

Page 80: ...eed to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation Oil System The oil tank is located on the left side of the vehicle To check the oil 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds Stop the engine 3 Remove the dipstick and wipe it dry with a clean cloth 4 Scr...

Page 81: ...a level surface Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine 2 Run the engine for two to three minutes then turn it off 3 Place a drain pan beneath the oil tank and remove the drain plug 1 Allow the oil to drain completely 4 Install a new sealing washer 2 on the oil drain plug NOTE The sealing surfaces on the drain plug and the oil tank should be ...

Page 82: ... plug and crankcase should be clean and free of burrs nicks or scratches 11 After draining reinstall the drain plug 12 Remove the dipstick 2 and add two quarts 1 9 l of Polaris Premium 4 synthetic oil see page 115 Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 13 Place the gear selector in neutral and set the parking brake 14 Start the engine and let it idl...

Page 83: ...t level should be checked every six months or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the vehicle on a level surface remove the fill plug and check the lubricant level The level should be 1 5 8 from the top of the fill hole A Add Polaris Premium Synthetic Gearcase Lubricant if necessary See page 115 for part numbers for Polaris recommended products...

Page 84: ...d check for leaks 8 Reinstall the footwell Front Gearcase Lubrication The front gearcase lubricant level should be checked every six months or 1000 miles 1600 km whichever comes first Front gearcase oil should be changed annually 1 Place the vehicle on a level surface and remove the fill plug 1 2 View the oil level and add oil if needed Oil should be kept at the bottom of the fill plug thread Use ...

Page 85: ...nging Procedure 1 Place the vehicle on a level surface Place a drain pan under the drain plug remove the plug 3 and allow the oil to drain Discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 3 Remove the fill plug and add 10 ounces 300 ml of Premium Front Gearcase Fluid see page 115 4 Check the oil level Oil level should be kept even w...

Page 86: ...llow the manufacturer s mixing recommendations for the freeze protection required in your area Cooling System Operation The engine coolant level is controlled or maintained by the recovery system The recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperature increases the expanding heated excess coo...

Page 87: ...essure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part NOTE To ensure that the coolant maintains its ability to protect the engine we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixt...

Page 88: ...mp and remove the filter 4 Remove the fabric type pre filter 1 from the main filter 2 Wash the pre filter in soapy water rinse and allow it to dry thoroughly 5 Reinstall the pre filter over the main filter Replace the main filter if necessary 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp or filter damage may occur CAUTION Operating the vehicle without ...

Page 89: ...t the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if necessary 3 Check hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter with the arrow pointing toward the engine Reinstall the clamps Operation of your vehicle without a breather filter can cause engine damage Always reinstall the breather filte...

Page 90: ... illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover im...

Page 91: ...se nuts and bolts are found see your dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer ...

Page 92: ...ther part of the vehicle when turned fully to the left or right 4 Lightly tighten each bolt equally to prevent uneven gaps in the block 5 Torque the handlebar adjuster block bolts to 10 12 ft lbs 14 16 Nm 6 Replace the headlight pod WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block bolts can cause limited steering or loosening of the handlebars resulting in ...

Page 93: ...be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 115 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 surface condition of the disc NOTE Pads should be cha...

Page 94: ...d when worn to 3 64 1 cm which is about the thickness of a U S dime Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Your vehicle s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliar...

Page 95: ...t until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Freeplay Adjustment Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever Flip ...

Page 96: ...ase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overhe...

Page 97: ...d and outward to disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward until t...

Page 98: ... the wheel nuts and remove the wheel Operating your PTV with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your PTV and in the owner s manual Always use original equipment size and type when replacing tires ...

Page 99: ...e tire point toward forward rotation 2 Attach the wheel nuts and finger tighten them NOTE Make sure the tapered end of the rear wheel nut goes into the taper on the wheel 1 3 Lower the vehicle to the ground 4 Torque the wheel nuts to 20 ft lbs 27 Nm Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by ...

Page 100: ...ed by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark P...

Page 101: ...e still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 7 Repeat steps 3 through 6 until no more particles are expelled when the engine is revved 8 Stop the engine and allow the arrestor to cool Reinstall the arrestor...

Page 102: ...s with electric start 7 Dry the spark plug and reinstall or replace with a new plug 8 Tighten the carburetor drain screw 9 Reinstall the crankcase drain 10 Turn the fuel valve on 11 Attempt to start the engine If necessary repeat the drying procedure 12 Take the machine to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the...

Page 103: ...NG Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates a...

Page 104: ...f cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into the battery 2 1 Battery electrolyte is poisonous It contains sulfuric acid Serio...

Page 105: ...e the battery vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle Becareful not to tip it sideways and spill electrolyte 1 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the ...

Page 106: ...e black negative cable 5 Reinstall the battery cover and attach the hold down strap 6 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed ...

Page 107: ...remove the pod cover 5 Unplug the headlamp from the wiring harness 6 Remove the boot and locking collar from the back of the lamp housing 7 Grasp the base of the lamp and lift it out 8 Reverse the previous steps to replace the lamp and reassemble the pod Make sure the tab on the lamp locates properly in the housing WARNING Poor lighting while driving can result in severe injury or death Headlight ...

Page 108: ...hree screws in the back of the headlight pod 5 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 6 Start the engine and turn the headlight switch to high beam 7 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on the wall NOTE Include rider weight...

Page 109: ...ses from the speedometer Unplug the indicator light harness and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Remove the o ring 1 from the headlight pivot pins 6 Pull the headlight housing up to release from the locking tabs 7 Lift the adjusting knob up to remove from the locking tabs 8 Carefully pull the assembly up and out of pod 9 Reverse the steps to install the new hous...

Page 110: ...t with a new lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the upper headlight pod to access the back of the indicator panel 2 Using a small straight blade screwdriver turn the base of the bad bulb 1 4 turn counter clockwise 3 Use a needle nose plier or similar tool to pull the lamp out of the indicator panel...

Page 111: ...e fuel system It s best to allow 15 20 minutes of operation for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl completely Oil And Filter Warm the engine and change oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter In...

Page 112: ...tenance Remove the battery and add distilled water as required to the proper level Do not use tap water which may contain minerals that reduce battery life Apply Polaris Di Electric Grease see page 115 to the terminal bolts and terminals Charge the battery at 1 4 amps or less until specific gravity of each cell is 1 265 or greater Store the battery in a cool dry place Charge can be maintained easi...

Page 113: ...off the engine and remove the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the vehicle to the transporting unit securely using suitable straps or rope 5 Always place the transmission in gear and lock the parking brake ...

Page 114: ...ound EBS Engine Type 4 Cycle Single Cylinder Displacement 499 cc Bore 3 6248I 92 mm Stroke 2 955I 75 mm Valve Clearance In Ex 0 006 0 006I TDC on compression Cooling Liquid Lubrication Type Dry Sump Operating RPM 200 6000 RPM Idle RPM 200 lights off 1200 RPM Compression Ratio 10 2 Full Stroke Compression Pressure 70 90 psi 15 Electrical Flywheel I D FF97 CDI Marking CU2570 Alternator Output 250 Wa...

Page 115: ...l 2 qts 1 9 L Brakes Dot 3 Shift Selector Box 1 oz 30 ml Drive Train Front Drive Ratio 3 7 1 Shaft Final Drive Ratio 3 1 1 Shaft Brake Hand Single Lever Hydraulic Disc Brake Auxiliary Foot Hydraulic Load Capacity Front Rack Std 90 lbs 40 9 kg Rear Rack Std 180 lbs 81 7 kg Tongue Weight 35 lbs 15 9 kg Tow Hitch Std Tow Capacity 1225 lbs 556 2 kg Dimensions Total Width 46I 116 84 cm Total Length 81I...

Page 116: ... 5 157 5 Over 1800 Over 6000 155 150 Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 20 54 PN5631214 Blue Green PN 7041157 White Yellow PN 7041635 45 37 PN 5133631 1800 3700 6000 12000 10 MH PN 5630513 Blue Green PN 7041157 White Yellow PN 7041635 45 37 PN 5133631 ...

Page 117: ... 8 oz 2871654 Premium Drive Hub Fluid 8 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease Nyogelt Coolant 2871323 60 40 Coolant gal 2871534 60...

Page 118: ...t in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plu...

Page 119: ...se ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 120: ... battery voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See your Polaris dealer Other mechanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See you...

Page 121: ...ottle quickly and effectively for effi cient engagement Belt slippage from water or snow ingestion into the PVT system Shift the transmission to neutral Using the throttle vary the engine RPM from idle to full throttle Repeat several times as required Dur ing this procedure the throttle should not be held at the full position for more than 10 seconds Clutch seals should be inspected for damage if ...

Page 122: ...Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE VEHICLE No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will b...

Page 123: ...osion or defects in parts components or the vehicle due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels that are not compatible with the vehicle The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replacement of any defective materials or components or product...

Page 124: ... Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate pe...

Page 125: ...edures 55 Driving Safely 55 58 67 Driving Through Water 64 Driving Uphill 60 E Electrical Switches 38 Electronic Speedometer 48 50 Engine Cooling System 84 85 Engine Idle RPM Adjustment 93 Equipment Modifications 11 F FEATURES 48 50 Filter Systems 86 87 Fog The Engine 110 Front Wheel Hub Tightening 97 Fuel Filter 45 Fuel Safety 36 Fuel System 45 Fuel Tank 45 Fuel Valve 45 G Gear Selector Operation...

Page 126: ...he Parking Brake 44 Side Panel Removal 95 Signal words and symbols 7 Spark Arrestor 69 99 Spark Plug Removal 98 Spark Plugs 98 S SPECIFICATIONS 112 114 Speedometer 48 50 Starting a Cold Engine 53 Starting a Warm Engine 54 Starting the Engine 53 54 Steering Inspection 89 Stop Switch 38 Storage Tips 109 110 Switches and Indicators 38 39 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 108...

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