Polaris 1998 Offroad Vehicle Page 95 Owner'S Manual Download

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MAINTENANCE

Lubrication Recommendations

4WD

17. Steering Post Bushings

25. Tie Rod End

13. Ball Joint

14. Front A-Arm

Pivot Shaft

Lower

Upper

11. 4

O’clock

position

11. Demand 4 Hubs

17. Steering Post Bushings

25. Tie Rod Ends

13. Ball Joint

14. Front A-Arm

Pivot Shaft

Lower

Upper

Trail Boss

Summary of Contents for 1998 Offroad Vehicle

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Page 3: ...wn to cause cancer birth defects or other reproductive harm A card containing important ATV safety information should be attached to the owner s manual on the next page If you cannot locate this card...

Page 4: ...YOUR SPORT Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended mainten...

Page 5: ...properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or drugs before or while operating this ATV Never op...

Page 6: ...de or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt...

Page 7: ...bstantial safety hazard Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which incr...

Page 8: ...l free insurance telephone number is 1 800 473 0111 The chance to arrange travel through the Polaris Travel Center The toll free travel telephone number is 1 800 267 1915 The chance to apply to serve...

Page 9: ......

Page 10: ...34 CONTROL AND PARTS FUNCTIONS 35 54 STARTING THE ENGINE 55 VEHICLE BREAK IN PERIOD 56 57 RIDING GEAR 58 CARRYING LOADS 59 CARGO WEIGHT DISTRIBUTION 60 DAILY PRE RIDE INSPECTION 61 RIDING 62 72 BATTER...

Page 11: ...ronment SAFETY TRAINING When you purchased this vehicle your dealer presented a hands on safety training course covering all aspects of ATV safety In addition you were provided with cer tain printed m...

Page 12: ...hich could result in serious injury or death CAUTION Indicates a potential hazard which may result in minor personal inju ry or damage to the ATV NOTE The word NOTE in this manual will alert you to ke...

Page 13: ...your protection Read and follow the instructions on each decal carefully In the event any decal becomes il legible or comes off contact your Polaris dealer for a replacement Any safety de cal needing...

Page 14: ...4 SAFETY WARNING AND OPERATION DECALS 1...

Page 15: ...5 SAFETY WARNING AND OPERATION DECALS 2...

Page 16: ...brakes carefully aggressive braking may result in flipover Avoid backing downhill Avoid turning at sharp angles in reverse USE OVERRIDE FOR REVERSE SPEED LIMITER WITH CAUTION itallows full engine powe...

Page 17: ...7 SAFETY WARNING AND OPERATION DECALS 4 5 6 7 6 3...

Page 18: ...LOSS OF CONTROL LOSS OF CONTROL CAN CAUSE SEVERE INJURY OR DEATH DO NOT OVERLOAD THE ATV SEE YOUR OWNER S MANUAL 7072786 7 WARNING Operating this ATV if you are under the age of 18 increases your chan...

Page 19: ...80 lbs on the rear rack ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARR...

Page 20: ...Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW ON THE RACK AS POSSIBLE Carrying loads high on the rack rais...

Page 21: ...E QUENT CLEANING REQUIRED IN DUSTY CONDITIONS DLiutilisation de ce v hicule sous li l ment filtre endommage s v rement le moteur DNettoyer souvent le filtre air surtout dans des situations poussiereus...

Page 22: ...OR EXCESSIVE ENGINE RPM EXCESSIVE ENGINE RPM CANCAUSE PART FAILURE RESULTING IN POSSIBLE SEVERE INJURY OR DEATH DO NOT MODIFY ENGINE ORCLUTCH 9 10 BELT CLUTCH GUARD COVERS MOVING PARTS CONTACT WITH MO...

Page 23: ...ee Owner s Manual Torque Eccentric Bolts To 60 Ft Lbs Le jeu libre de la chaine est important crasez la suspension pour L adjuster Prenez soin de ne pas trop serrer la chaine Voir le manuel d op rateu...

Page 24: ...adjustment and fluid level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop...

Page 25: ...ed in the course and the operating tech niques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTI...

Page 26: ...Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harmto youand or yourpassenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to al...

Page 27: ...V s tires are designed for off road use only not for use on pavement Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE...

Page 28: ...ic streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many...

Page 29: ...our chances of a se vere head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an a...

Page 30: ...and perception Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPP...

Page 31: ...G POTENTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or...

Page 32: ...enance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during op eration WHAT CAN HAPPEN Removing even one hand or foot...

Page 33: ...WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra c...

Page 34: ...HAPPEN Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain unt...

Page 35: ...tice turning at low speeds before attempting to turn at faster speeds Do not turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more...

Page 36: ...s described in the Owner s Manual See pages 65 through 68 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weigh...

Page 37: ...for going down hills as described in the Owner s Manual See page 67 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any h...

Page 38: ...nd on any hill until you have mas tered the turning technique as described in the Owner s Manual on level ground See page 68 Be very careful when turning on any hill Avoid crossing the side of a steep...

Page 39: ...ght uphill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply...

Page 40: ...g or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go s...

Page 41: ...than that specified in your Owner s Manual See page 69 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let fric...

Page 42: ...tire pressure as described in the Owner s Manual Supplement POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this...

Page 43: ...ways follow the instructions in the Owner s Manual for carrying car go or pulling a trailer See pages 59 and 60 After a rollover or an accident have a qualified service dealer check the complete machi...

Page 44: ...ignition key num ber here It is a four digit number found stamped on the key In the event the key is lost replacement can be made by supplying your dealer with this number Ignition Key Number The veh...

Page 45: ...Stop Switch The engine will not start or run when the switch is in its off position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other eme...

Page 46: ...ffers with individual models and not every model is equipped with all the lights The informa tion in your Owner s Manual Supplement and in the following box willhelp youiden tify the lights on your ma...

Page 47: ...designed for off road use only and must not be ridden on streets or highways Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness NOTE The taillig...

Page 48: ...choke and throttle settings during starting WARNING The Electronic Throttle Control ETC limits engine power in the event of a throttle system malfunction and is provided for your safety Do not attemp...

Page 49: ...st Do not store or use a partial bottle of brake fluid Brake fluid is hygro scopic meaning it rapidly absorbs moisture from the air This causes the boiling temperature of the brake fluid to drop which...

Page 50: ...g brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the down...

Page 51: ...e WARNING Use caution when applying the auxiliary mechanical brake Do not aggressively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of contr...

Page 52: ...n heavy pulling situations to extend belt life To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle...

Page 53: ...engage NOTE The override switch also allows ac tivation of Demand 4 Drive AWD in reverse if Demand 4 Drive switch is on The AWD button position and a red AWD light indicates when the vehicle is in De...

Page 54: ...death If the hubs remain engaged after following these instructions return the ATV to your dealer for service PVT System WARNING The PVT system rotates at high speeds creating large amounts of force...

Page 55: ...led coolant is drawn back up from the tank past the pres sure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the sys tem is purging itself of trapped air Observe c...

Page 56: ...cover on the front of the ATV just below the oil cap Us ing a flat stubby screwdriver loosen the screw 1 4 turn and pull the cover forward and up to remove Gen III To access the pressure cap clean th...

Page 57: ...aris recommends the use of Polaris Pre mium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum com patible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is alre...

Page 58: ...AUTION To avoid serious engine damage always top off the oil level when refueling CAUTION On models with a twocycle engine use onlyPolaris injectionoil Never substitute or mix oil brands Serious engin...

Page 59: ...enti lated area DDo not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored DDo not over fill the tank Do not fill the tank neck DIf you g...

Page 60: ...k and wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angle and depth of stick consistent 5 Remove dips...

Page 61: ...en by hand 1 2 to 3 4 turn after gasket contact 12 Approximately 1 cup of engine oil will remain in the crankcase To drain remove drain plug found on lower right side of crankcase NOTE The sealing sur...

Page 62: ...ide improved overall engine cleanli ness With new generation lubricity technology they excel in meeting the lubrica tion demands of today s high performance 2 cycle engines These are optimum oils reco...

Page 63: ...e compressor senses when the engine is spinning fast enough to start and restores compression for starting 1 Be certain your vehicle is on a level surface and the parking brake is set See page 40 2 Ta...

Page 64: ...coil housing if the starter handle is disengaged from the rope guide when under water After travelling in wet areas the recoil housing and starter should always be drained completely by removing the r...

Page 65: ...engine does not start release starter button and wait five seconds then press starter button for another five se conds Repeat this procedure until engine starts NOTE Do not press the throttle while st...

Page 66: ...d will give you room to fa miliarize yourself with vehicle operation and handling 4 Vary the throttle positions CAUTION Do not operate at full throttle or high speeds for extended periods during the f...

Page 67: ...aded or leaded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil reservoir level in dicated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and...

Page 68: ...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 hel met face shield of...

Page 69: ...bs 213 kg 90 lbs 41 kg 180 lbs 82 kg Magnum 4X4 470 lbs 213 kg 90 lbs 41 kg 180 lbs 82 kg Trail Boss 325 148 kg No Front Rack 125 57 kg Sport 400 L 200 91 kg No Front Rack No Rear Rack Trail Blazer 20...

Page 70: ...ds can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Car rying loads high on the racks raises the cent...

Page 71: ...adjustment and fluid level includes auxiliary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop...

Page 72: ...ermine 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 and all trans...

Page 73: ...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 t...

Page 74: ...and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engaged can assist in control ling the vehicle in slippery areas CAUTION Never engage Demand Drive while wheels are...

Page 75: ...g 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV WARNING Braking and handling are greatly affected whenever operating in hilly ter rain Loss of v...

Page 76: ...d the hill while keep ing your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismoun...

Page 77: ...e rear of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs W...

Page 78: ...left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or slightly down ward 6...

Page 79: ...e 4 After crossing dry the brakes by applying light pressure to the lever until brak ing action is normal CAUTION Should your ATV become immersed it will be necessary to take it to your dealer as soon...

Page 80: ...antly alert for hazards such as logs rocks and low hanging branches WARNING Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obst...

Page 81: ...th caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Only open the throttle enough to maintain a de sired speed Opening the throttle more than required may ca...

Page 82: ...the transmission in gear 3 Set the parking brake 4 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above 5 Shut off fu...

Page 83: ...clean rags Coat the terminals with dielectric grease or petro leum jelly Do not allow cleaning solution or tap water to enter the battery It will shorten the life of the battery Vehicle lamps will bur...

Page 84: ...first black negative cable last 1 Set the battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause...

Page 85: ...BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engi...

Page 86: ...the machine onto an incline so the rear of thema chine is one foot higher than the front Set the park ing brake and block the wheels Make sure the ma chine is in neutral and re peat steps 2 and 3 WAR...

Page 87: ...area when purging the spark arrestor DWear eye protection DDo not stand behind or in front of the vehicle while purging the carbon from the spark arrestor DNever run the engine in an enclosed area The...

Page 88: ...shock spring preload selected models NOTE Other tools are also necessary to perform maintenance work They are called out later in this manual Power Pig Tail Some models are equipped with an auxiliary...

Page 89: ...ical repair More often under severe use such as dirty or wet conditions L Emission Control System Service California 4 Cycle Item Hours or Odometer Frequency Remarks L Engine Oil Level Change 4 Cycle...

Page 90: ...Drain moisture out after riding in water General Lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc Front hubs fluid check AWD 50 hrs 6 months Check monthly Front hubs fluid change A...

Page 91: ...Brake pad wear 10 hrs 100 miles Monthly Inspect periodically Auxiliary As required As required Inspect deflection daily adjust Tires Pre ride Pre ride Inspect daily pre ride inspection item Wheels Pre...

Page 92: ...ittings and Grease Every 3 months or 50 hours 7 Front Prop Shaft U joints Grease Locate Fittings and Grease Every 3 months or 50 hours 8 Front Prop shaft Yoke Grease Locate fittings and grease 3 pumps...

Page 93: ...side opposite chain and grease Every 3 months or 50 hours 21 Upper Control Arms Grease Locate fittings and grease Semi annually 22 Lower Control Arms Grease Locate fittings and grease Semi annually 2...

Page 94: ...mmendations Operating Range Full 4 Transmission 7 Front Prop Shaft U Joint 12 Axle Cardan Front Drive AWD Models 6 Rear Halfshaft U Joint 8 Propshaft Yoke 9 Speedo meter Cable Fill plug 5 Front Gear C...

Page 95: ...Steering Post Bushings 25 Tie Rod End 25 Tie Rod End 13 Ball Joint 14 Front A Arm Pivot Shaft Lower Upper 11 4 O clock position 11 Demand 4 Hubs 17 Steering Post Bushings 25 Tie Rod Ends 13 Ball Joint...

Page 96: ...ENANCE Lubrication Recommendations 17 Steering Post Bushings 13 Ball Joint 14 Front A Arm Pivot Shaft Lower Upper 25 Tie Rod End 13 Ball Joint 14 Front A Arm Pivot Shaft 11 4 O clock position 11 Deman...

Page 97: ...g Arm Bushings 18 Rear Axle Bearing Forward 16 Output shaft sup port bearing grease fit ting 20 Center and Front Eccentrics 21 Upper Control Arm 23 Rear Wheel Hub Bearing Carri er 24 Rear Anti Roll Ba...

Page 98: ...CE Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 25 Hrs 50 Hrs 75...

Page 99: ...ars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 10 to 12 ft lbs NOTE Tighten bolts so there is an equal gap at the fr...

Page 100: ...el Nuts 50 Ft Lbs Front Spindle Nut s Dealer Performed Service 4x4 Front Wheel Nuts 15 Ft Lbs 4x4 Chain Drive Rear Axle Nut s 80 Ft Lbs Rear Wheel Nuts 50 Ft Lbs Front Spindle Nut s Dealer Performed S...

Page 101: ...ANCE Rear Spring Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension Rear Spring Adjustment Rear Spring Adju...

Page 102: ...n 7041546 067 STANDARD 100 lb in 7041519 067 OPTION 140 lb in Sportsman 500 4x4 Front Strut Spring 7041238 067 OPTION 61 lb in 7041375 067 STANDARD 64 113 lb in 7041450 067 OPTION 101 lb in Xplorer 30...

Page 103: ...N 64 113 lb in Trail Blazer Rear Compression Spring N A 7041470 093 STANDARD 150 lb in 7041389 067 OPTION 175 lb in Trail Blazer Front Strut Spring N A 7041471 093 STANDARD 41 lb in 7041238 067 OPTION...

Page 104: ...hind 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 tab 3 To reinstall side pan...

Page 105: ...a gray collar from the air box Do not re move the collar 4 Carefully wash the yellow foam boot in soapy water and dry it 5 Oil the foam boot with engine injec tion oil 1 to 2 teaspoons Squeeze out the...

Page 106: ...tion of air box and replace if necessary Install filter into airbox Be sure filter element seats securely 8 Check cover gasket and replace if required Be sure cover is seated properly and wing nuts ar...

Page 107: ...ect the gasket It should adhere tightly to the cover and seal all the way around 5 Remove the wing nut and wash er securing the second cover The cover should be straight and not distorted 6 Remove the...

Page 108: ...d by hot soapy water 3 Rinse and dry thoroughly 4 Inspect element for tears or damage 5 Apply foam filter oil or clean engine oil and squeeze until excess oil is removed 6 Reinstall pre filter element...

Page 109: ...o the cover and seal all the way around 5 Remove the wing nut and washer securing the second cover The cover should be straight and not distorted 6 Remove pre filter from main fil ter and discard them...

Page 110: ...s Squeeze out the excess into an absorbant cloth 7 Reinstall the yellow foam boot onto the air filter box 8 Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be...

Page 111: ...ngnuts securing the airbox lid and remove lid 3 Pull foam breather filter out 4 Loosen clamp and removefilter 5 Remove foam pre cleaner from main filter 6 Wash the pre filter in soapy wa ter and dry i...

Page 112: ...tion abrasion or leaks Replace as needed 5 Reinstall filter and clamps with arrow pointing toward engine Reinstall heat shield NOTE Breather filter life is longer when airbox pre filter is in place Ne...

Page 113: ...dged in the foam wash in high flash point solvent Gently squeeze out excess solvent and dry Do not oil 4 Push foam filter straight down into airbox until flush with upper edge of box Make sure foam is...

Page 114: ...used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands in front of the machine perpendicular to the rear tires 3...

Page 115: ...iaphragm should be replaced Always fill the reservoir as indicated whenever the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid PN 2870990 WARNING Once...

Page 116: ...to be used as a backup for the hydraulic service brake system Should the hydraulic system fail the rear brake can be acti vated by depressing the foot pedal on the inside of the right floorboard NOTE...

Page 117: ...bolt coun terclockwise until brake engage ment starts at approximately 1 2 of the total pedal travel See Il lustration 2 Type II If adjustment is neces sary loosen jam nut A and turn adjuster bolt B...

Page 118: ...able to the point where the carb slide is just starting to rise 5 Lift boot up off adjuster sleeve Re move the oil pump cover Loosen the cable adjuster locknut Adjust oil pump cable until marksalign D...

Page 119: ...ore throttle slide starts to open 4 Place very slight pressure on the throttle lever until all freeplay is re moved from throttle cable to the point where the carb slide is just starting to rise 5 Loo...

Page 120: ...ir is out of the system Throttle Cable Adjustment 400 Engines Vehicles with 400 engines do not utilize a cable sleeve jam nut You will need to bottom the cable to the carburetor slidevalve cap Adjust...

Page 121: ...the engine will be hard starting when cold and the half on choke position used for inter mittent applications will not function Choke Adjustment Procedure 1 Flip choke toggle to the full off position...

Page 122: ...2 to 1 turn by turning the screw clockwise DDuring hot weather and or high altitude operation the air screw can be ad justed for smooth operation by approximately 2 turns counterclockwise Choke Adjust...

Page 123: ...gear with the parking brake applied 3 Adjust the carburetor idle screwin or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turn ing the screw out counterclock...

Page 124: ...firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injection oil improper use of the choke or in...

Page 125: ...be kept at the full mark on the dipstick The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Transmission Oil Changing Procedure 1 Remove skid plate 2...

Page 126: ...level surface remove fill plug and check the lubricant level Lubricant should be kept at the full mark on the bottom of fill plug threads The correct gearcase lubricant to use is GL5 80 90 Weight Gea...

Page 127: ...and locate dipstick 2 Remove dipstick Oil level is shown on dipstick 3 Add SAE 10W30 oil with a trans mission fluid funnel until oil is at the proper level on the dipstick See Ill If overfilled exces...

Page 128: ...ove the wheel Wheel Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the outside and...

Page 129: ...type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less Please refer to your Owner s Manual Supplement for tire specifications WARNING Op...

Page 130: ...ont or center drive chain too loose or too tight as severe damage to the transmissionand drivecompo nents can result Periodically remove the chain guards to check chain quality and adjustment The cent...

Page 131: ...ard or rearward until a sprocket hole aligns with hole pro vided in eccentric 7 Insert a large punch or screwdriver through gear and into eccentric hole Ro tate vehicle rearward to tighten chain Chain...

Page 132: ...axle to the transmis sion output shaft intersecting the swing arm pivot This establishes the tightest chain position At this point the chain should have 1 4 1 2 6cm 1 3cm deflec tion If the chain nee...

Page 133: ...wise and remove bulb 3 Install bulb into headlight housing and rotate clockwise firmly NOTE bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector High Beam...

Page 134: ...erminal board and jumper 6 Mount cover to machine 7 Properly adjust headlight aim Headlight Adjustment 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a wall 2 Me...

Page 135: ...f the ATV covering the radiator cap by us ing a stubby flat screwdriver to dis engage the screw Remove the door and set it aside 6 Disengage the tabs at the front of the upper panel where they snap in...

Page 136: ...am can be adjusted to any position desired by turning the four screws at the outer corners of the lamp housing 1 Place the vehicle on a level surface with the headlight approximately 25 7 6 m from a w...

Page 137: ...speedometer cable Unplug indi cator lights from harness and remove pod cover 4 Unplug headlamp from wiring harness 5 Remove boot and locking collar from back of lamp housing 6 Grasp base of lamp and l...

Page 138: ...3 Lift pod cover up Using a pliers discon nect speedometer cable Unplugindica tor lights from harness and remove pod cover 4 Unplug headlamp from wiring harness 5 Remove O Ring from headlight pivot p...

Page 139: ...ator Lamp Replacement Style I 1 With a small flat screwdriver gently pry loose the indicator light cover 2 Using a small flexible tube such as an oil delivery hose grasp the burned out lamp and remove...

Page 140: ...and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your a Po laris dealer for free replacement Waxing Your ATV can be waxed with any quality brand automotive pas...

Page 141: ...its operation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approxi mately 3 of its power for each 1000 foot 304 8 m increase inelevation Alth...

Page 142: ...Water in Fuel Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse o...

Page 143: ...d 8520149 72060 1998 Trail Blazer Rims Bright White 85200153 2185 1998 Springs Fire Red 8520149 72060 1998 Scrambler 400 Rims Bright White 8520153 2185 1998 Springs Black 8520147 9440 1998 Scrambler 5...

Page 144: ...num N A N A 1998 Springs Burnished Brown 8520264 N A 1998 Xplorer 400 Rims Brushed Aluminum N A N A 1998 Springs Black 8520147 9440 1998 Sportsman 500 Rims Black 8520147 9440 Springs Bonnie Blue 85201...

Page 145: ...ilgate 2871495 2871495 2871495 2871495 Utilitiy Trailer N A 2871498 N A 2871498 Utility Trailer Rubbermaid N A 2871338 N A 2871338 Windshield Kit Clear 2870864 2870864 2870864 2870864 Fairing Kit Blac...

Page 146: ...2870684 2870790 2870948 2870948 2871495 2871495 2871495 2871495 2871495 2871495 2871498 N A N A 2871498 2871498 2871498 2871338 N A N A 2871338 2871338 2871338 2870864 2871324 2871324 2870864 2871324...

Page 147: ...870799 2870799 Reverse Warning Kit Sound 2870991 2870991 2870991 2870991 Hour Meter 2871011 2871011 2871011 2871011 8 hp 40 Rear Mower N A 2871457 N A 2871457 10 5 hp 40 Rear Mower N A 2871491 N A 287...

Page 148: ...80799 2980799 2980799 2980799 2980799 2980799 2870991 2870991 2870991 2870991 2870991 2870991 2871011 2871011 2871011 2871011 2871011 2871011 2871457 N A N A 2871457 2871457 2871457 2871491 N A N A 28...

Page 149: ...ack Kit 2871357 STD 2871357 STD Front Rack Extender 3 5 N A 2871502 N A 2871499 Front Rack Extender 8 N A N A N A 2871318 Rear Rack Extender 3 5 N A 2871504 N A 2871501 Rear Rack Extender 8 N A 287091...

Page 150: ...0 Xplorer 400 Xplorer 500 STD 2871357 2871357 STD STD STD 2871502 N A N A 2871499 2871499 2871499 2870931 N A N A 2871318 2871318 2871318 2871503 N A N A 2871501 2871501 2871501 2870942 N A N A 287131...

Page 151: ...pair Rear 2870948 2870948 Ramps for Pick up Tail gate 2871495 2871495 Utilitiy Trailer 2871498 2871498 Utility Trailer Rubber maid 2871338 2871338 Windshield Kit Clear 2870864 2871324 Fairing Kit Bla...

Page 152: ...2871313 2871313 Cover Camo 2871084 2871084 Safety Whip Flag 2870799 2870799 Reverse Warning Kit Sound 2870991 2870991 Hour Meter 2871011 2871011 8 hp 40 Rear Mower 2871457 2871457 10 5 hp 40 Rear Mowe...

Page 153: ...4x4 Sportsman 500 Accessory Winch Kit 2871461 2871461 Front Rack Kit STD STD Front Rack Extender 8 2870931 2871318 Rear Rack Extender 3 5 2871503 STD Rear Rack Extender 8 2870942 2871319 Gun Shovel H...

Page 154: ...nty Registration Form will be the warranty entitlement If you have not signed the original registration and re ceived the customer copy please contact your dealer immediately NO WAR RANTY COVERAGE WIL...

Page 155: ...PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to...

Page 156: ...Wheel Hubs 44 Draining Recoil Housing 54 Drive Chain Adjustment 120 Engine Choke Adjustment 113 Engine Choke Adjustment 400 111 Engine Electrical Switches 35 Engine Idle Rpm Adjustment 113 Engine Idl...

Page 157: ...n Gear Selector Operation 42 Transmission Lubrication 115 Transmission Oil Changing Procedure 115 Transporting 131 Traveling Downhill 67 Traveling Uphill 65 Troubleshooting 132 Turning Around On A Hil...

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