Polaris 2004 Sportsman 6x6 Page 131 Owner'S Manual For Maintenance And Safety Download

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128

INDEX

Noise Emission Control System

. . . .

Odometer

. . . . . . . . . . . . . . . . . . . . .

Oil Change

83-84

. . . . . . . . . . . . . . . . . .

Oil Filter Change

83-84

. . . . . . . . . . . . .

Oil Pump Priming

. . . . . . . . . . . . . . .

Oil System

. . . . . . . . . . . . . . . . . . . .

Operating Safety

. . . . . . . . . . . . . . . .

OPERATION

52-70

. . . . . . . . . . . . . . . .

Operator Safety

7-33

. . . . . . . . . . . . . . . .

Override Switch

. . . . . . . . . . . . . . . .

Parking on an Incline

. . . . . . . . . . . .

Periodic Maintenance Schedule

74-77

. .

POLARIS PRODUCTS

118

. . . . . . . . .

Pre-Ride Inspection

. . . . . . . . . . . . . .

Premium 4 Synthetic Lubricant

. . . . .

Programmable Service Interval

. . . . .

PVT System

102-103

. . . . . . . . . . . . . . .

Radiator Coolant Level

. . . . . . . . . . .

Recoil Housing

105

. . . . . . . . . . . . . . . .

Recoil Starter

. . . . . . . . . . . . . . . . . .

Recovery Bottle Coolant Level

. . . . .

Reverse Speed Limiter

. . . . . . . . . . .

Rider Information Center

48-51

. . . . . . .

Safe Riding Gear

. . . . . . . . . . . . . . . . .

SAFETY

6-33

. . . . . . . . . . . . . . . . . . . . .

Safety Decals and Locations

13-16

. . . . .

Safety Training

. . . . . . . . . . . . . . . . . .

Service Brakes

. . . . . . . . . . . . . . . . .

Setting the Parking Brake

. . . . . . . . .

Side Panel Removal

. . . . . . . . . . . . .

Sidehilling

. . . . . . . . . . . . . . . . . . . .

Spark Arrestor

71, 104

. . . . . . . . . . . . . .

Spark Plug Removal

101

. . . . . . . . . . . .

Spark Plugs

101

. . . . . . . . . . . . . . . . . . .

SPECIFICATIONS

116-117

. . . . . . . . . .

Starting a Cold Engine

. . . . . . . . . . .

Starting a Warm Engine

. . . . . . . . . .

Steering Inspection

. . . . . . . . . . . . . .

Stop Switch

. . . . . . . . . . . . . . . . . . . .

Storage Tips

114

. . . . . . . . . . . . . . . . . .

Suspension Springs

. . . . . . . . . . . . . .

Switches and Indicators

36-37

. . . . . . . . .

Taillight/Brakelight

Lamp Replacement

112

. . . . . . . . .

Throttle Lever

. . . . . . . . . . . . . . . . . .

Tire Specifications

100

. . . . . . . . . . . . .

Tire Tread Depth

. . . . . . . . . . . . . . . .

Toe Alignment

. . . . . . . . . . . . . . . . .

Tool Kit

. . . . . . . . . . . . . . . . . . . . . . .

Torque Specifications

100

. . . . . . . . . . .

Towing Capacities

. . . . . . . . . . . . . . .

Transmission Lubrication

. . . . . . . . .

Transmission Oil Change

. . . . . . . . .

Transporting the Vehicle

115

. . . . . . . . .

Trip Meter

. . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING

119-122

. . . . . .

Turning Around on a Hill

. . . . . . . . .

Vehicle Break-in

. . . . . . . . . . . . . . . .

VEHICLE IDENTIFICATION

NUMBERS

. . . . . . . . . . . . . . . . .

WARRANTY

125-126

. . . . . . . . . . . . . .

Warranty

123-124

. . . . . . . . . . . . . . . . . .

Washing the ATV

113

. . . . . . . . . . . . . .

Waxing the ATV

113

. . . . . . . . . . . . . . .

WELCOME

. . . . . . . . . . . . . . . . . . . .

Wheel Installation

. . . . . . . . . . . . . . .

Wheel Removal

. . . . . . . . . . . . . . . .

Summary of Contents for 2004 Sportsman 6x6

Page 1: ......

Page 2: ......

Page 3: ...ed to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance The engine exhaust from this product contains chemicals kno...

Page 4: ...ted a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustrie...

Page 5: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 6: ...ehicle 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 conta...

Page 7: ...e is stolen these numbers are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key bla...

Page 8: ...E 3 VEHICLE IDENTIFICATION NUMBERS 4 SAFETY 6 FEATURES AND CONTROLS 35 OPERATION 52 EMISSION CONTROL SYSTEMS 71 MAINTENANCE AND LUBRICATION 73 SPECIFICATIONS 116 POLARIS PRODUCTS 118 TROUBLESHOOTING 1...

Page 9: ...stitute 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 protecti...

Page 10: ...Polaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the opera...

Page 11: ...n 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 cauti...

Page 12: ...ve maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals All information in this manual is based on the latest product d...

Page 13: ...eld 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...

Page 14: ...ppery 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...

Page 15: ...t 1 800 342 3764 Additional Important Information We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris...

Page 16: ...w only from tow hooks or hitch Maximum Front Rack Load 75 lbs IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI Kpa FRONT 5 34 5...

Page 17: ...S DUse an approved HELMET AND PROTECTIVE GEAR DAvoid paved surfaces Pavement may seriously affect handling and control DUse proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terra...

Page 18: ...7078254 Remove flammable containers from before refueling Maximum Box Load 800 lbs DPassengers can be thrown off This can cause serious injury or death DNever carry passengers ALL WHEEL DRIVE SWITCH...

Page 19: ...lter element will severely damage the engine S Clean air filter often more frequent cleaning required in dusty condi tions S Operation of this vehicle without en gine breather filter s can cause en gi...

Page 20: ...g 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 th...

Page 21: ...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 car...

Page 22: ...g an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating a Sportsman 6x6 without an approved helmet increases the risk of a severe head injury or death in the event of an...

Page 23: ...ou begin rolling backwards Keep your body weight toward the front of the vehicle uphill Do not apply engine power Do not apply the rear brakes Gradually apply the service brake When fully stopped appl...

Page 24: ...Always operate the vehicle at a speed that s proper for the terrain visibility and operating conditions and your experience POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The Sports...

Page 25: ...rocedures 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 c...

Page 26: ...ZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding ca...

Page 27: ...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 lo...

Page 28: ...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...

Page 29: ...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 thr...

Page 30: ...HAZARD Always follow proper procedures for traveling down hills as described in the owner s manual Always check the terrain carefully before descending a hill Shift your weight backward Never travel d...

Page 31: ...e Sportsman 6x6 around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 65 Use extra caution when turning on any hill Avoid crossing...

Page 32: ...ARD Overloading the vehicle or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO A...

Page 33: ...l 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 Wet brakes may hav...

Page 34: ...ire pressure 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...

Page 35: ...ZARD Operating the vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Consumption of alcohol and or drugs could seriously affect operator judgment Reaction time may be slower and operator balanc...

Page 36: ...r possible damage including but not limited to brakes throttle and steering systems CAUTION Exposure to hot components could result in a fire Always keep combustible materials away from the exhaust sy...

Page 37: ...34 NOTES...

Page 38: ...ATURES AND CONTROLS 1 Service Brake Lever 2 Middle Axle Auxiliary Brake Lever 3 Throttle Lever 4 Box Dump Latch Release 5 Gear Selector 6 Floorboards 7 Backrest 8 Cargo Box 9 Front Rack 1 2 3 4 4 5 6...

Page 39: ...n 3 Engine Stop Switch The engine will not start or run when the switch is off Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency...

Page 40: ...ockwise past the ON position Release the key when the engine starts The taillight is on whenever the main switch is on Turn the key off to prevent battery drain 5 All Wheel Drive AWD Switch Leaving th...

Page 41: ...C stops 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...

Page 42: ...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 oper...

Page 43: ...evel If the fluid level is low add DOT 3 brake fluid DO NOT OVERFILL See page 118 for the part numbers of Polaris products 2 1 An over full master cylinder may cause brake drag or brake lock up which...

Page 44: ...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...

Page 45: ...main supply 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 th...

Page 46: ...henever 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 ext...

Page 47: ...in the ON position NOTE If the engine is cold use the choke as outlined on page 55 4 Grasp the recoil starter rope handle 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other s...

Page 48: ...s regain traction the front wheels will automatically disengage NOTE The override switch 2 allows activation of AWD in reverse if the AWD switch is on There is no limit to the length of time the vehic...

Page 49: ...ewhat restricted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following this procedure return...

Page 50: ...fer to page 36 for additional information 1 Rider Information Center 2 Speedometer needle in addition to depicting vehicle speed this needle will flash to signal a fault condition 3 Speedometer 2 3 1...

Page 51: ...Meter 4 Service Interval Miscellaneous Service Warnings 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged A lo...

Page 52: ...rough the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles traveled by the ATV on each tri...

Page 53: ...d as a reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will...

Page 54: ...ooks similar to the top illustration and refers to the software version installed in your ATV This information is displayed briefly Use the mode reverse override button to toggle through the diagnosti...

Page 55: ...ank 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 G...

Page 56: ...slowly at first Select an open area that will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and...

Page 57: ...ts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain check condition and slack refer to drive chain adjustment procedure 9 Air cleaner element check for dirt clean or replace...

Page 58: ...TE Do not press the throttle while starting the engine 4 Turn the ignition key past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the switch when t...

Page 59: ...valve to ON sit on the vehicle and move the engine stop switch to RUN 3 If the engine has cooled to a point where it does not readily start intermittent use of the choke button pulled half way out ma...

Page 60: ...ndling and may cause loss of control or brake instability S Never exceed the stated load capacity for this vehicle S Do not obstruct the headlight when loading the front rack S Cargo should be properl...

Page 61: ...release lever forward 5 Lift the front of the cargo box and dump the cargo If the weight distribution in the box is located toward the rear of the box when the release lever is pulled forward the box...

Page 62: ...ed 4 Slow down 5 The 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 se...

Page 63: ...arm up 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 Ve...

Page 64: ...the inside 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 techniq...

Page 65: ...ansferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn t...

Page 66: ...3 Slow down 4 Apply the brakes slightly to aid in slowing Hard use of the braking system while descending a hill could result in a front end overturn causing serious injury or death Always operate th...

Page 67: ...e opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 15 Maximum WARNING Braking and handling are greatly affected when operating in hilly...

Page 68: ...ase 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...

Page 69: ...ody weight forward Never brake during a skid 3 Drive with AWD engaged to assist in controlling the vehicle in slippery areas Severe damage to the drive train may occur if the AWD is engaged while the...

Page 70: ...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 an...

Page 71: ...backing 6 Never activate the override button while the throttle is open Loss of control may result NOTE This vehicle is equipped with a reverse speed limiter The override button should be used with ca...

Page 72: ...on the downhill side See illustration 3 Shut off the fuel supply WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse gear alway...

Page 73: ...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 N...

Page 74: ...This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system The system does not allow the blow by gases to enter the atmosphere...

Page 75: ...72 NOTES...

Page 76: ...Spark plug wrench and handle S Torx wrench rack removal Accessories Polaris has a wide variety of accessories for your vehicle Contact your Polaris dealer for a complete list The addition of certain...

Page 77: ...inspected and serviced more frequently If you are not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust and replace...

Page 78: ...olaris dielectric grease to socket when replaced Tires Air pressure Pre ride Pre ride Inspect daily and before each use Brake system Pre ride Pre ride Inspect Wheels Pre ride Pre ride Inspect Frame nu...

Page 79: ...ssary Choke enrich er cable 50 hrs 6 months Inspect adjust lubricate re place if necessary Carburetor float bowl 50 hrs 6 months Drain bowl periodically and prior to storage Rear suspen sion 50 hrs 6...

Page 80: ...onths Inspect clean surface Cooling system 100 hrs 12 months Inspect hoses Engine mounts 100 hrs 12 months Inspect Spark plug 100 hrs 12 months Inspect replace if necessary Front hubs 100 hrs 12 month...

Page 81: ...Synthetic Gearcase Lube Fill to bottom of the filler hole Change annually or at 100 hrs Front Prop Shaft Yoke Loc 1 FGrease Locate Fittings and Grease Every 3 mos or 50 hrs AWD Hubs Loc 2 Premium Hub...

Page 82: ...79 MAINTENANCE AND LUBRICATION Lubrication Recommendations Inner Tie Rod End A Loc 1 Loc 2 Loc 3 Loc 4 Loc 5 Loc 6 Loc 7 Loc 8...

Page 83: ...level at the bottom of the fill hole 2 The proper level is 1 5 8 from the top of the fill hole NOTE Do not fill to the bottom of the fill hole threads 3 Reinstall the fill plug and propshaft shield T...

Page 84: ...h the vehicle on a level surface remove fill plug 1 2 View the oil level and add the recommended oil as needed Oil should be kept at the bottom of the fill plug thread 3 Replace the fill plug Gearcase...

Page 85: ...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...

Page 86: ...ath 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 shoul...

Page 87: ...in 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 o...

Page 88: ...CE 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...

Page 89: ...ressure 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...

Page 90: ...low 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 r...

Page 91: ...clamp 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 to dry thoroughly 5 Reinstall the pre filter over the main...

Page 92: ...TE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if necessary 3...

Page 93: ...ear tires See 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 fr...

Page 94: ...que the rear two bolts A gap of up to 1 8 will remain at the rear bolts Optional Suspension Springs Although the Polaris Sportsman 6x6 suspension has the capability of providing the best ride possible...

Page 95: ...e 40 Under normal functioning the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be rep...

Page 96: ...essive wear Throttle Cable Free Play Adjustment Throttle cable free play is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn th...

Page 97: ...ert a pin punch 3 through the sprocket hub and into the eccentric axle housing 5 Roll the vehicle ahead or back to adjust chain slack to the proper dimension 6 Tighten the caliper mount bolts to 10 12...

Page 98: ...ngine Idle RPM Adjustment Recommended engine idle RPM is 1200 200 If the engine idle speed is unsatisfactory and all other conditions are favorable the carburetor can be adjusted as follows 1 Start th...

Page 99: ...0 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 overheating or PVT or engine damage See y...

Page 100: ...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 l...

Page 101: ...orrect position on the wheel hub Be sure the valve stem is toward the outside and the rotation arrows on the tire point toward forward rotation 4 Attach the wheel nuts and finger tighten them Make sur...

Page 102: ...ld lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Use of non standard size or type of tires or improper tire inflation may adve...

Page 103: ...800 lbs 363 kg Front Rack Load Capacity 75 lbs 34 kg Gross Vehicle Weight 1970 lbs 894 kg including vehicle driver and cargo Vehicle weighs 895 lbs 406 kg The following items should be checked for tig...

Page 104: ...caused 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 t...

Page 105: ...above the engagement speed of 1200 1400 RPM However in high range at 3 MPH 5 KPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be r...

Page 106: ...G 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 occu...

Page 107: ...and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 until no more particles are expelled when the engine is revved 6 Stop the engine and allow the arrestor to cool Reinst...

Page 108: ...ing any time the vehicle has been operated in very wet conditions and also before storage The drain screw 1 is located at the bottom of the recoil housing above the front propshaft Remove the screw wi...

Page 109: ...ife It can also hinder vehicle performance Follow the battery charging instructions on page 107 before installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the batter...

Page 110: ...other fluid to this battery The single most important thing to maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must us...

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 mon...

Page 112: ...arness 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...

Page 113: ...gh beam 4 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 on the seat wh...

Page 114: ...eadlight pod 3 Lift the pod cover Disconnect the speedometer harnesses from the speedometer and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Pull the headlight housing up to re...

Page 115: ...ot work the lamp may need to be replaced 1 Remove the taillight lens cover mounting screws Remove the lens cover and gasket and set aside for reassembly 2 Remove the lamp 1 and replace it with the rec...

Page 116: ...d safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system...

Page 117: ...Turn the engine over several times using the recoil starter to ensure coverage of piston rings cylinder walls and crankshaft bearings 5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fue...

Page 118: ...nother unit 1 Turn off the engine and remove the key to avoid loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap and oil cap are installed correctly 4 Always tie the frame of th...

Page 119: ...learance 5 5 in 14 cm Dry Weight 895 lbs 406 kg Minimum Turning Radius 119 in 302 cm unloaded Engine Oil Capacity Two quarts 1 89 liters Gearcase Oil Capacity 32 oz 95 liters Coolant Capacity 2 25 qua...

Page 120: ...wheel Headlight 1 Single Beam on Handlebar 50 w 2 Single Beam on Grill 27 w Taillights 8 26W Brakelight 26 9W Instrument Cluster LCD Jetting Chart Altitude AMBIENT TEMPERATURE Below 40 F Below 5 C 40...

Page 121: ...p for Gearcase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Seaso...

Page 122: ...cient engagement Stuck in mud or snow Carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large...

Page 123: ...e 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 Cr...

Page 124: ...e ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel vent line Inspect and repla...

Page 125: ...battery voltage Recharge battery to 12 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Elec...

Page 126: ...tlement If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WI...

Page 127: ...LAIMS ALL EXPRESS WARRANTIES 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 you if inconsistent with co...

Page 128: ...ling 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 Co...

Page 129: ...d outside of the country where it was pur chased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin cover age of any kind Ve...

Page 130: ...se 68 69 Driving on Slippery Surfaces 66 Driving Over Obstacles 70 Driving Procedures 60 Driving Safely 59 70 Driving Through Water 67 Driving Uphill 64 Dumping Cargo 58 E EMISSION CONTROL SYSTEMS 71...

Page 131: ...Service Brakes 39 Setting the Parking Brake 41 Side Panel Removal 97 Sidehilling 62 Spark Arrestor 71 104 Spark Plug Removal 101 S Spark Plugs 101 SPECIFICATIONS 116 117 Starting a Cold Engine 55 Sta...

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