Polaris Sportsman 9920775, Owner'S Manual

Page 1: ...s important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age 2007 Sportsman 6X6 Owner s Manual for Maintenance and Safety 2007 Sportsman 6X6 Owner s Manual for Maintenance and Safety ...

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Page 3: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 4: ...r 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 Technician Your Polaris dealer knows your vehicle best and is i...

Page 5: ...and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is...

Page 6: ...TS Know Your Vehicle 5 Safety 6 Features 34 Operation 50 Emission Control Systems 69 Maintenance 70 Adjustments 115 Troubleshooting 120 Specifications 124 Polaris Products 126 Warranty 127 Maintenance Log 137 Index 140 ...

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Page 8: ... in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame VIN _______________________________________________...

Page 9: ...trol USE ALCOHOL or DRUGS before or while operating this vehicle Operate at speeds too fast for your skills or the conditions Operate this vehicle on HILLS steeper than 15 degrees To prevent flipover on hilly terrain use throttle and brakes gradually ALWAYS Use an approved HELMET AND PROTECTIVE GEAR Avoid paved surfaces Pavement may seriously affect handling and control Use proper RIDING TECHNIQUE...

Page 10: ...in bed and firmly secured to the rack 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 or box Read Owner s Manual for more detailed loading information Front Rack Box Warning WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or h...

Page 11: ... WARNING Passengers can be thrown off This can cause serious injury or death Never carry passengers Maximum Box Load 800 lbs 363 kg Clutch Cover Warning WARNING NO STEP Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can re...

Page 12: ...h switch to engage AWD if the rear wheels are spinning This may cause severe drive shaft and clutch damage See your Owner s Manual Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG ...

Page 13: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the l...

Page 14: ...ersonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a je...

Page 15: ...n severe injury or death A Polaris ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions Read and understand your owner s manual and all warnings before operatin...

Page 16: ...ng procedures You should review this information on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at 800 887 2887 or by visiting www atvsafety org Purchasers of a used Polaris ATV will be charged for this training A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operatio...

Page 17: ...rt symbol on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note ...

Page 18: ...perate an ATV on a public street road or highway including a dirt or gravel road Never operate an ATV without wearing 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 Never consume alcohol or drugs before or while operating an ATV Never operate at excessive speeds Travel at speeds appropriate for the ...

Page 19: ...f a hill at high speed Always follow proper procedures for going downhill and for braking on hills Check the terrain carefully before you start down a hill Shift your weight uphill Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Drive straight downhill Always follow proper procedures for crossing the side of a hill Av...

Page 20: ...ing water If necessary apply them lightly several times to allow friction to dry out the pads Always check for obstacles or people behind the ATV before operat ing in reverse When it s safe to proceed in reverse move slowly and avoid turning at sharp angles Always use the size and type of tires specified for your ATV and always maintain proper tire pressure Never modify an ATV through improper ins...

Page 21: ...iginal equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers or large rack...

Page 22: ...se and the operating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org WARNING POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a ...

Page 23: ...m the vehicle which could result in serious injury HOW TO AVOID THE HAZARD Never carry a passenger WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control accident and or injury ...

Page 24: ... POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet 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 AVOI...

Page 25: ...operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV WARNING POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident causing severe injury or death HOW TO AVOID THE ...

Page 26: ... Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures and sche...

Page 27: ...ld contact the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn...

Page 28: ...te on excessively rough slippery or loose terrain until you ve learned and practiced the skills necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for ...

Page 29: ...e loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 15 degrees Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill ...

Page 30: ...which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills WHAT CAN HAPPEN Improperly crossing or turning as hills could cause loss of control or overturn HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level grou...

Page 31: ...service brakes Lock the parking brake when fully stopped Never back down a hill If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rolling backwards Apply the service 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 ATV is pointed straight uphill...

Page 32: ...les such as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual WARNING POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and...

Page 33: ... 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 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 WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN Th...

Page 34: ...bed in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling which could lead to an accident HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories All parts and accessories added to the vehi...

Page 35: ...ity for this ATV 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 WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operato...

Page 36: ...sabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death WARNING Exhaust system components are very hot during and after use of the vehicle Hot components can cause serious burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling ...

Page 37: ...rse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 45 All Wheel Drive AWD Switch See page 43 for AWD information WARNING Activating the override switch while the throttle is open can cause loss of control resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Swi...

Page 38: ... engine slide the stop switch to the center RUN position and turn the main key switch clockwise past the ON position Release the key when the engine starts Headlight Switch Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position WARNING Operating the ATV on streets or roads especially...

Page 39: ...ause an accident and lead to severe injury or death Never start or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before sta...

Page 40: ... the reservoir fluid level before riding The lever should feel firm when squeezed Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before operating See your dealer for proper diagnosis and repairs Auxiliary Brake Lever The auxiliary brake lever is located on the right handlebar It controls braking action for the middle axle rear brake o...

Page 41: ...oir 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 To ensure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain ...

Page 42: ...ds The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill posi tion Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling WARNING Operating the ATV whil...

Page 43: ... valve is located on the left side panel It has three positions OFF For vehicle storage and when transporting ON For normal operation RES For reserve supply if main sup ply is exhausted There s about a 7 to 10 mile 11 2 to 16 km range on the reserve supply Always refill the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling Fuel Tank...

Page 44: ...ck the parking brake 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 use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time CAUTION Shifting gears with the e...

Page 45: ... is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause dama...

Page 46: ...will automatically disengage NOTE The override switch allows activation of AWD in reverse if the AWD switch is on See page 34 There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction CAUTION Switching...

Page 47: ...d gear NOTE If the hubs remain engaged after following this procedure return the vehicle to your dealer for service To continue using AWD while operating in reverse activate both the override switch and the AWD switch See page 34 Tool Kit To help you perform routine maintenance a tool kit is provided in the storage compartment under the seat Items included in the kit are Screwdriver Open end wrenc...

Page 48: ...information NOTE In addition to showing vehicle speed the speedometer needle flashes when a warning condition exists CAUTION High water pressure may damage ATV components Wash the ATV by hand or with a garden hose using mild soap Certain products including insect repellents and chemicals will damage the speedometer lens and other plastic surfaces Do not use alcohol to clean the instrument cluster ...

Page 49: ...r This indicator illuminates when the electrical por tion of the AWD system is enabled 3 Engine Hour Display Indicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged A low battery warning may also occur under normal oper ation if the machine is at idle and high electr...

Page 50: ...The trip meter records the miles traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 NOTE In the Rider Information Center the trip meter display contains a deci mal point but the odometer displays without a decimal point Mode 3 Hour Meter This mode logs the tot...

Page 51: ...onds 2 Lock the parking brake 3 Place the transmission in neutral 4 Hold the mode reverse override button and turn the key switch on 5 Release the switch as soon as the display is activated The initial screen display refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnostic screens Screen 1 Batte...

Page 52: ...s to flash release the button The set ting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait for the wrench to stop flashing When the wrench stops blinking your service hours are set NOTE If you scroll past the intended number hold the butt...

Page 53: ... not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Turn the fuel valve off whenever the vehicle is stored or parked WARNING The engine exhaus...

Page 54: ...hrottle 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 7 During the break in period change both the oil and the filter at 20 hours or one month PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better...

Page 55: ...ct ensure fastener tightness 88 89 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 40 77 Coolant level if applicable Ensure proper level 83 84 Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 36 116 Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 35 Air filter pre filter Inspect clean 90 Ai...

Page 56: ...is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off dur ing operation as excess fuel washing into the engine oil will increase wear on engine components NOTE If the knob doesn t stay where positioned increase the tension by rotating ...

Page 57: ...e of the choke button pulled half way out may be nec essary If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 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 10 If the engine slows or stops position the choke knob half way in to al...

Page 58: ...ow and forward in the cargo box as possible Reduce speed and allow a greater distance for braking Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill Always attach the tow load to the hitch point Do not tow any trailer on a grade steeper than 15 Vehicle should never exceed 10 mph 16 kph while towing a load on a level surface ...

Page 59: ...ever forward 6 Lift the front of the cargo box to dump the cargo 7 Lower the cargo box Make sure the latch is secure before operating WARNING If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward the box may dump on its own which could cause serious injury Never operate the dump lever without checking the position of the load This will...

Page 60: ...he cargo box dump latch must be securely latched before loading and operating Unintentional box tilting will result if weight is placed in the rear of the box and the latch is not secured WARNING Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle The cargo box could close unexpectedly and injure the driver The rear tires will also catch the rear ...

Page 61: ...n the handlebars 3 Start the engine and allow it to warm up See page 53 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 62: ...on slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while sup porting 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 speeds can result in v...

Page 63: ...urning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire...

Page 64: ...le opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 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 15 maximum Use extreme caution when operating on hills and follow proper oper...

Page 65: ...your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately WARNING 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 side of a hill when possi...

Page 66: ...E Before operating your ATV learn how to use the auxiliary brake for emergency situations if service brakes become inoperable WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death Slow down Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate the brakes slightly whe...

Page 67: ...e is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 6 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill 7 Start the engine with the transm...

Page 68: ...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 it s impo...

Page 69: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING 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 ...

Page 70: ...earward vehicle speed is greatly increased Do not operate at wide open throttle 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 movement Use with cauti...

Page 71: ...ncline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side 5 Turn the fuel valve off ...

Page 72: ...ww gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition Th...

Page 73: ...service and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style high...

Page 74: ...nterval whichever comes first Remarks Hours Calendar Miles Km Q Steering Pre Ride Make adjustments as need ed See Pre Ride Checklist on page 52 X Front suspension Pre Ride X Rear suspension Pre Ride Tires Pre Ride X Brake fluid level Pre Ride X Brake lever travel Pre Ride Brake system Pre Ride Wheels fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter ...

Page 75: ...ect level change yearly X E Engine breather filter if equipped 25 H Monthly 155 250 Inspect clean if needed X General lubrication 50 H 3 M 310 500 Lubricate all fittings pivots cables etc Shift linkage 50 H 6 M 310 500 Inspect lubricate adjust Q Steering 50 H 6 M 310 500 Lubricate X Front suspension 50 H 6 M 310 500 Lubricate X Rear suspension 50 H 6 M 310 500 Lubricate Carburetor float bowl 50 H ...

Page 76: ...100 H 12 M 620 1000 Inspect clean external surfaces X Cooling hoses if applicable 100 H 12 M 620 1000 Inspect for leaks X Engine mounts 100 H 12 M 620 1000 Inspect Exhaust muffler pipe 100 H 12 M 620 1000 Inspect Q E Spark plug 100 H 12 M 620 1000 Inspect replace as needed Q E Ignition Timing 100 H 12 M 620 1000 Inspect X Wiring 100 H 12 M 620 1000 Inspect for wear routing security apply dielectri...

Page 77: ...ail Do not overfill Transmission Oil Polaris Premium Synthetic Gearcase Lube See page 81 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles before long periods of storage or after pres sure washing or submerging AWD Hubs Premium Demand Drive Hub Fluid Remove set screw in hubs Rotate wheels to 4 00 position see illus tration on next page If lubricant...

Page 78: ... MAINTENANCE Lubrication Recommendations Front Prop Shaft Yoke AWD Hubs Ball Joint Middle Axle Bearings Center Swing Arm Housing Swing Arm Bushings Rear Axle Bearing Rear Strut Tie Rod Ends 4 00 Position ...

Page 79: ...kdown in ambi ent temperatures from 40 F to 120 F 40 to 49 C Its excep tional frictional properties result in more efficient operation more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used...

Page 80: ...Wipe it dry with a clean cloth 4 Reinstall the dipstick securely NOTE The dipstick must be fully installed to ensure an accu rate measurement 5 Remove the dipstick and check the oil level 6 Add oil as needed Maintain the oil level in the safe range Do not overfill NOTE If the oil level rises above the full safe mark water and or fuel may be collect ing in the tank Change the oil Dipstick Safe Full...

Page 81: ... on drain plug and crankcase should be clean and free of burrs nicks or scratches 6 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 7 Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank Clean the fitting NOTE The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal tape CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to c...

Page 82: ...ew filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface then turn it an additional 1 2 turn 14 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 15 Reinstall the ...

Page 83: ... 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 45 60 seconds 3 Remove the vent line clamp If the line is bled properly you should hear a rush of air indicating that the line is properly primed and ready for operation NOTE If you do not hear air the line has not bled Repeat the priming proce dure ...

Page 84: ... Remove the fill plug 4 Check the oil level Add the recom mended gearcase oil as needed to bring the level to the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 14 ft lbs 19 Nm 6 Reinstall the propshaft shield Oil Change 1 Position the vehicle on a level sur face Remove the propshaft shield from the right side of the vehicle 2 Place a drain pan under the gearcase 3 Remove the ...

Page 85: ...rcase oil as needed to bring the level to the bottom of the fill hole threads 5 Reinstall the fill plug Torque to 14 ft lbs 19 Nm Oil Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the gearcase The drain plug is located on the bottom right hand side of the gearcase 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the...

Page 86: ... is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle Polaris recommends the use of Polaris Premium 60 40 anti freeze cool ant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water See page 126 for the ...

Page 87: ...ded remove the four screws securing the front compart ment to the vehicle 3 Place your fingers under the front of the compartment and pull upward to remove it 4 Remove the pressure cap 5 Using a funnel slowly add coolant through the radiator filler neck 6 Reinstall the pressure cap NOTE Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer f...

Page 88: ... Axle Brake The front wheel and middle axle brakes are hydraulic disc brakes These brakes are self adjusting and require no adjustment The following checks are recommended to keep the brake systems in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 38 2 Check the brake system for fluid leaks 3 Check...

Page 89: ...ear tires on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear measure ment should be 1 16 to 1 8 2 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service WARNING Severe injury or death can result from improper toe alignme...

Page 90: ...rm motion pull the panel forward and out ward 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 side panel to disengage 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 up...

Page 91: ...Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical com ponent operations All service must be performed by your authorized Polaris dealer WARNING Operating your ATV 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 pro...

Page 92: ...l nuts to specification Axle and Wheel Nut Torque Specifications Check the following nuts for tightness occasionally and when they ve been loosened for service WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin ins...

Page 93: ...n rinse and let dry 5 Reinstall the pre filter over the main filter NOTE Install a new main filter if needed 6 Reinstall the filter into the air box and tighten the clamp Do not over tighten the clamp as filter damage could occur 7 Reinstall the air box cover and the seat Air Box Drain Periodically check the air box drain tube located on the bottom rear of the air box Empty the drain tube if neces...

Page 94: ... direction of the arrow to check for clogging Replace a damaged or clogged filter 3 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 4 Reinstall the filter with the arrow pointing toward the air box Secure the hose clamps NOTE The breather filter is intended to be used with the air box pre filter in place Without the pre filter the breather filter can clog quickly CAUTI...

Page 95: ...nnect the speedometer harnesses from the speedometer 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Turn the lamp counterclockwise to remove it 7 Apply dielectric grease to the socket and install the new lamp NOTE Make sure the tab on the lamp locates properly in the housing 8 Reassemble the pod WARNING Poor lighting while driving can result in s...

Page 96: ...or to the center of the headlight and make a mark on the wall at the same height 3 Start the engine Turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall NOTE Include rider weight on the seat when measuring 5 The adjustment knob is located on the right side of the headlight pod...

Page 97: ...s 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove it from the locking tabs 8 Carefully pull the assembly up and out of the pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE The distance from the head lamp parting line to the end of...

Page 98: ...taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly 2 Remove the lamp 3 Apply dielectric grease to the socket and install the new lamp 4 Test the light for proper opera tion 5 Reinstall the gasket and lens cover Lens Cover Lamp ...

Page 99: ...for correct color See page 97 1 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 2 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specifi cation CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plug...

Page 100: ...r over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended oil or incorrect throttle body adjustments Recoil Housing Always drain the recoil housing after operating the vehicle in wet condi tions Drain the housing before storing the vehicle Make sure the hous ing is completely dry before reinstalling the drain plug 1 Stop the eng...

Page 101: ...eral times using the electric start 8 Dry the spark plug Reinstall the plug or install a new plug 9 Tighten the carburetor drain screw 10 Turn the fuel valve on 11 Attempt to start the engine If necessary repeat the drying pro cedure 12 Take the ATV to your dealer for service as soon as possible whether you succeed in starting it or not 13 If water has been ingested into the PVT follow the procedu...

Page 102: ...the wheels 8 Place the transmission in neutral Lock the parking brake Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrestor to cool 10 Reinstall the arrestor plug and remove the exhaust outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death The exhaust system can get extr...

Page 103: ...itional loads on components The PVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owne...

Page 104: ... to the system s dependence on engine speed For example when operating at a ground speed of 3 MPH 5 km h in low range the engine speed would be around 3000 RPM This is well above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 km h the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low t...

Page 105: ...rottle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to settle to idle speed then shift the trans mission to the lowest available range 4 Test for belt slippage If the belt slips repeat the process 5 Take the vehicle to your dealer for service as soon as possible Condition Range to U...

Page 106: ...th clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk o...

Page 107: ...careful not to tip a conventional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last CAUTION If electrolyte spills immediately wash...

Page 108: ...tional batteries install the battery vent tube sealed bat teries do not have a vent tube NOTE The vent tube must be free of obstructions and securely installed If not battery gases could accumulate and cause an explosion The tube should be routed away from the frame and body to prevent corro sion Avoid skin contact with electrolyte which can cause severe burns 4 Connect and tighten the red positiv...

Page 109: ...can be maintained by using a Polaris Battery Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 126 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained batte...

Page 110: ... be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 If the voltage is less than 12 8 volts recharge the battery at 1 2 amps or less until battery voltage is 12 8 or greater NOTE When using an automatic charge...

Page 111: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 112: ...ith a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish CAUTION High water pressure may damage c...

Page 113: ...ris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid th...

Page 114: ...n 4 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 5 Turn the engine over several times using the recoil starter Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 Treat the fuel system with Polaris Carbon Clean See page 112 7 If Polaris fuel system additive is not used the fuel tank fuel lines ...

Page 115: ...ill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instructions on the container for the recommended amount NOTE Carbon clean will also reduce the possibility of bacterial growth in the fuel system 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank Oil and Filter Change the oil and filter See p...

Page 116: ...e Area Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power fo...

Page 117: ...ngine 2 Place the transmission in gear 3 Lock the parking brake 4 Secure the fuel cap oil cap and seat 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets 6 Remove the key to prevent loss during transporting ...

Page 118: ...achine when turned fully to the left or right 4 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear of the clamp blocks WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and pos...

Page 119: ...expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Lock Nut Adju...

Page 120: ...5 Roll the vehicle forward or rear ward to adjust chain slack to the proper dimension 6 Tighten the caliper mount bolts to 10 12 ft lbs 13 5 16 3 Nm 7 Tighten the eccentric locking bolts to 60 ft lbs 80 Nm 8 Confirm correct tension by rolling the vehicle forward checking chain tension in several places around the chain 9 Reinstall the chain guard NOTE Reposition the chain guide to allow 1 8 3 mm c...

Page 121: ...Optional Suspension Springs Although the suspension has the capability of providing the best ride possible the following accessory springs are available to better suit individual riding preferences NOTE Optional springs may be a different color than standard springs Springs may be painted to a desired color using Polaris touch up paint available through Polaris dealers Front Strut Spring 7041375 0...

Page 122: ... and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area NOTE Pilot screws are sealed with metal plugs and are serviceable only by Polaris dealers Carburetor Engine Idle RPM...

Page 123: ... Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Shift the transmission to low range and carefully use fast brief aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of contro...

Page 124: ...tive spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Possible Cause Solution Weak spark from spark plug Inspect clean and or ...

Page 125: ...l Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel...

Page 126: ...tion connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core c...

Page 127: ...cm Overall Width 46 in 117 cm Overall Height 48 in 122 cm Wheelbase 77 in 196 cm Ground Clearance 5 5 in 14 cm Dry Weight 895 lbs 406 kg Minimum Turning Radius 119 in 302 cm unloaded Engine EH50PLE104 Displacement 499 cc Bore x Stroke 92 x 75 mm Alternator Output 250W 5000 RPM Compression Ratio 10 2 1 Starting System Electric w recoil backup Carburetor BST 34 Pilot Jet 40 Main Jet 142 5 Needle Jet...

Page 128: ...lic Disc Brake Auxiliary Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Handlebar 50 watt 2 Single Beam on Grill 27 watt Taillights 8 26 watts Brake Light 26 9 watts Instrument Cluster LCD Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Meters Feet 0 1800 0 6000 10 MH PN 5630513 Blue Green PN 7041157 Red PN 7041198 40 PN 5131446 2 2 1800 3700 ...

Page 129: ...d Drive Hub Fluid 2 5 gal Coolant 2871323 60 40 Coolant gal 2871534 60 40 Coolant qt 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 NyogelTM 2...

Page 130: ...s dealer REGISTRATION At the time of sale the Warranty Registration 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 No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitle ment If you have not signed the ...

Page 131: ...or defects in parts com ponents 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 products THE...

Page 132: ...our 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 person at Polaris This warranty gives you specific legal rights and you may also have other rights which vary from state to state If any of the abov...

Page 133: ...eling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized Polaris dealer You must show...

Page 134: ...red outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for war ranty or service bulletin coverage of any kind Vehicles registered to Government offi cials or military personnel on assignment outside of the country where the vehicle was purchased will continue to be covered by the basic warranty For questions c...

Page 135: ...ARIS will repair your LSI engine at no cost to you including diagnosis parts and labor Manufacturer s Warranty Coverage The 2006 and later LSI engines are warranted for two 2 years If any emission related part on your LSI engine is defective the part will be repaired or replaced by POLARIS Owner s Warranty Responsibilities As the LSI engine owner you are responsible for the performance of the requ...

Page 136: ...t is defective Any warranted part which is not scheduled for replacement as required maintenance or which is scheduled only for regular inspection to the effect of repair or replace as nec essary shall be warranted for the warranty period Any warranted part which is sched uled for replacement as required maintenance shall be warranted for the period of time up to the first scheduled replacement of...

Page 137: ...ne or any warranted emission related part unless performed by an authorized dealer c Failure to use recommended fuel as specified in the 2006 and later Owner s Manual d Repairs and diagnosis performed outside of an authorized dealer e Use of parts which are not authorized by POLARIS Maintenance Schedule The LSI engine owner is responsible for having all scheduled inspection and mainte nance servic...

Page 138: ...t parts will be provided at no charge if the part is still under warranty How to File a Warranty Claim Where to Get Warranty Service All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the LSI engine or a dealer authorized by POLARIS In the event that any emis sion related part is found to be defective during the warranty period you must notify the Polaris...

Page 139: ...f any defective materials components or prod ucts THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR RANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI DENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR RANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE A...

Page 140: ... 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 ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 141: ...138 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 142: ...139 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 143: ...etrain Break In 51 Driving Downhill 63 Driving in Reverse 67 Driving on a Sidehill 62 Driving on Slippery Surfaces 60 Driving Over Obstacles 66 D Driving Procedures 58 Driving Safely 58 68 Driving Through Water 65 Driving Uphill 61 Dumping Cargo 56 E Electromagnetic Interference 69 Emissions Limited Warranty 136 Engaging AWD 43 Engine Break In 51 Engine Fogging 111 Engine Idle RPM Adjustment 119 E...

Page 144: ...ont Rack Box Warning 7 General Warning 6 Hitch Capacity Label 9 Reverse Override Warning 7 Tire Pressure Load Warning 7 S Safety Training 13 Severe Use 70 Side Panel Removal 87 Sidehilling 62 Signal Words 14 Spark Arrestor 99 Spark Plug Recommendations 96 Spark Plugs 96 97 Starting the Engine 53 54 Steering Assembly 87 Storage Tips 111 113 Suspension Springs Optional 118 Switches AWD Switch 43 Eng...