Polaris 2007 Outlaw Owner'S Manual Download Page 111 | Manualshive

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108

MAINTENANCE AND LUBRICATION

Oil and Filter Change

14. Replace the o-ring in the cover.
15. Lubricate the gasket on the new filter with a film of fresh engine oil.
16. Reinstall the spring and install the new filter with the open end facing outward.
17. Install the cover and torque the bolts to 72-78 in. lbs. (8-9 Nm).

NOTE:

The long bolt must be placed in the forward hole.

Step 14

Step 16

Step 17

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Summary of Contents for 2007 Outlaw

Page 1: ......

Page 2: ......

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: ...1...

Page 5: ...gn and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publicatio...

Page 6: ...a Polaris vehicle and welcome to our world wide family of Polaris owners We proudly produce an exciting line of utility and recreational products S Snowmobiles S All terrain vehicles ATVs S RANGER uti...

Page 7: ...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...

Page 8: ...Y 8 FEATURES AND CONTROLS 48 OPERATION 67 EMISSION CONTROL SYSTEMS 90 MAINTENANCE AND LUBRICATION 92 ADJUSTMENTS 146 CLEANING AND STORAGE 167 TROUBLESHOOTING 176 POLARIS PRODUCTS 183 SPECIFICATIONS 18...

Page 9: ...on about all aspects of your vehicle including safe operating procedures Vehicle Identification Numbers Record your ATV s identification numbers and key number in the spaces provided Remove the spare...

Page 10: ...7 KNOW YOUR VEHICLE Vehicle Identification Numbers Vehicle Model Number Frame VIN 1 left side Engine Serial Number 2 right side Key Number 3 2 1 31XX 3...

Page 11: ...efully If any of the decals depicted in this manual differ from the decals on your ATV always read and follow the instructions of the decals on the ATV If any decal becomes illegible or comes off cont...

Page 12: ...o fast for your skills or the condi tions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALW...

Page 13: ...vehicle for off road use only in sport type recreation and competitive use by operators with advanced skills and substantial experience Discretionary Warning 4 WARNING S Never operate this vehicle on...

Page 14: ...in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY Gross Vehicle Weight INCLUDING MACHINE DRIVER AND CARGO IS 660 LBS 299 kg Reduce speed and allow gr...

Page 15: ...helmet that meets or exceeds 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...

Page 16: ...nal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean 3 Gloves Off road style gloves with knuckle pads are the best for comfort and p...

Page 17: ...utine 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 operating a Polaris ATV Operat...

Page 18: ...rials that explain safe operating 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 Expr...

Page 19: ...is involved when these words and symbols are used Become familiar with their meanings before reading the manual The safety alert symbol on your vehicle or in this manual alerts you to the potential fo...

Page 20: ...caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will...

Page 21: ...hasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm Contact ATV Enrollment Express at 800 887 2887 or visit www atvsafety org for information on en...

Page 22: ...ate at excessive speeds Trav el at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt jumps or other stunts S Always inspect your ATV before eac...

Page 23: ...fore attempting larger hills S Always follow proper procedures for climbing hills Check the terrain careful ly before ascending a hill Never climb hills with excessively slippery or loose surfaces Shi...

Page 24: ...duce the chance of skidding or sliding out of con trol S Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hil...

Page 25: ...imes to allow friction to dry out the pads S Always check for obstacles or people be hind the ATV before operating in re verse When it s safe to proceed in reverse move slowly and avoid turning at sha...

Page 26: ...purposes Any modifications to the original 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 equi...

Page 27: ...situations and on different types of terrain HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA They should then re...

Page 28: ...skill and experience recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a beginner or inexperienced driver operates this ATV HOW TO AVOID THE HAZARD Only operators...

Page 29: ...ion operates this ATV Even though a child may be within the recommended age group for operating some ATVs he she may not have the skills abilities or judgment needed to operate an ATV safely and could...

Page 30: ...reduces the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of...

Page 31: ...nd 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 32: ...streets roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads...

Page 33: ...et 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...

Page 34: ...perating 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 th...

Page 35: ...NG POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Attempting stunts increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt jumps or other s...

Page 36: ...tain 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 ope...

Page 37: ...or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footpeg it could come into contact with t...

Page 38: ...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 HOW TO AVOID THE HAZARD Travel slowly and use ext...

Page 39: ...cessively 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 slip...

Page 40: ...ibed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Operating on excessively steep hills WHAT C...

Page 41: ...the owner s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your...

Page 42: ...res for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 81 Always check the terrain carefully before descend...

Page 43: ...t to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 82 Use extra caution when turning on any hill Avoid crossin...

Page 44: ...radually When fully stopped apply rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the rear brake while rollin...

Page 45: ...es 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 WH...

Page 46: ...through deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 87 travel slowly balance your weight carefully avoid sudden movements and mai...

Page 47: ...use the size and type of tires specified for the ATV in the owner s manual Always maintain proper tire pressure as described in the owner s manual and on safety decals WARNING POTENTIAL HAZARD Overlo...

Page 48: ...ling 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 vehicle must be genuine Pol...

Page 49: ...h the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could collide with an obstacle or per...

Page 50: ...e vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result...

Page 51: ...48 FEATURES AND CONTROLS Engine Electrical Switches 1 2 3...

Page 52: ...the switch is in the OFF position 3 Main Key Switch To start the engine the main key switch must be in the RUN position NOTE Both the main switch and the emergency engine stop switch will shut off al...

Page 53: ...FEATURES AND CONTROLS Instrumentation An illuminated light in the indicator window will alert you to the following conditions 1 Hot engine 2 Reverse gear is selected 3 Neutral gear is selected N R 3 1...

Page 54: ...ts It s designed for and must be used for off road use only Use caution and drive at reduced speeds in conditions of reduced visibility such as fog rain and darkness The light switch is located on the...

Page 55: ...rise 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 be...

Page 56: ...rottle lever the engine will stop and power to the rear wheels will cease WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for...

Page 57: ...r is located under the seat Maintain the fluid level between the minimum and maximum marks Check the rear brake light for proper operation before each use of the vehicle See page 120 WARNING Aggressiv...

Page 58: ...st brake lever travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level whic...

Page 59: ...ght glass 2 on the side of the master cylinder Maintain the fluid level at or slightly above the mark 3 near the center of the sight glass Do not overfill NOTE When checking the fluid level the ATV mu...

Page 60: ...e recommended level Do not overfill After opening a bottle of brake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs mo...

Page 61: ...parking brake is disengaged before operating Locking the Parking Brake 1 Place the transmission in first gear 2 Squeeze and release the brake lever two or three times then squeeze and hold 3 Push the...

Page 62: ...o prevent rolling S 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 position S Never depend on the parking brake...

Page 63: ...dlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use E 85 fuel Fuel Filter The fuel valve has an internal fuel filter Do not attempt to clean t...

Page 64: ...when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE There s about a 5 to 8 mile 8 to 13 km range on reserve gas Always refill the gas tank as soon as pos...

Page 65: ...OLS Choke The choke assists in starting a cold engine The choke knob 1 is located on the left side of the vehicle Refer to the engine starting procedure on page 72 for correct choke and throttle setti...

Page 66: ...eleased To upshift to a higher gear place the toe of your boot under the gear shift pedal and raise the pedal one full stroke To downshift place your foot on the gear shift pedal and depress the pedal...

Page 67: ...lever to disengage the clutch 4 Depress the gear shift pedal one full stroke to shift into first gear 5 Release the brake lever 6 Gradually squeeze the throttle lever while slowly releasing the clutch...

Page 68: ...ator from shifting into reverse unintentionally 1 Place the transmission in first gear See page 63 2 Push the lock out lever forward toward the handlebar to unlock the transmission 3 Shift down into r...

Page 69: ...a lower gear NOTE Be sure the engine RPM has sufficiently decreased before shifting to a lower gear WARNING Improper use of the brakes or shifting when the engine RPM is too high can cause the tires...

Page 70: ...where refueling is performed or where gasoline is stored S Do not overfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and wa ter...

Page 71: ...urs of cautious operation No single action on your part is as important as following the procedures for a proper break in Perform the following procedures carefully CAUTION Excessive heat build up dur...

Page 72: ...re operating 4 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 5 Vary the throttle positions Do not operate at sustained idle 6 P...

Page 73: ...de Checklist Item Remarks See Page Brake system lever travel Ensure proper operation 55 147 Brake fluid Ensure proper level 56 Foot brake Ensure proper operation 54 Clutch lever Check for proper opera...

Page 74: ...hes Ensure operation 49 Engine stop switch Ensure proper operation 49 Air filter pre filter Inspect clean 114 Headlamp Check operation apply Polaris dielectric grease to the socket when the lamp is re...

Page 75: ...on monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area CAUTION Operating the vehicle immediately after starting could cause engine...

Page 76: ...ion by rotating the tension adjusting nut clockwise FULL ON HALF ON OFF NOTE The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during oper...

Page 77: ...a maximum of five seconds Release the start button immediately when the engine starts NOTE Do not press the throttle lever while starting the engine NOTE Excessive engagement may result in starter da...

Page 78: ...e necessary If you believe the engine is over choked when warm push the choke lever completely in and depress the throttle lever fully while cranking to aid in starting Release the throttle lever imme...

Page 79: ...t to warm up then shift the transmission into gear See page 64 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thu...

Page 80: ...your upper body to the inside of the turn while supporting your weight on the outer footpeg This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly...

Page 81: ...iding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise care when operat...

Page 82: ...a steady rate of speed and throttle opening 5 Be alert and prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when o...

Page 83: ...Follow proper procedures as outlined in the owner s manual If you enter into a situation where sidehilling is unavoidable 1 Slow down 2 Lean into the hill transferring your upper body weight toward t...

Page 84: ...wnhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Shift to the lowest gear possible while maintaining a safe speed 5 Apply the foot brake slightly to aid in slowing WARNING Excess...

Page 85: ...s manual If the vehicle stalls while climbing a hill never back it down the hill One maneuver that can be used when it s necessary to turn around while climbing a hill is the K turn 1 Keep your body...

Page 86: ...ointing across the hill or slightly downward 7 With the front brakes still applied release the clutch lever and lock the parking brake Remount from the uphill side keeping body weight uphill 8 Pull in...

Page 87: ...rking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in first gear 3 Lock the parking brake 4 Always block the rear wheels on the...

Page 88: ...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 obs...

Page 89: ...s and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pre...

Page 90: ...starting the engine 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 av...

Page 91: ...riving in Reverse Follow these precautions when operating in reverse 1 Avoid backing downhill 2 Back slowly 3 Apply the brakes lightly for stopping 4 Avoid turning at sharp angles 5 Never open the thr...

Page 92: ...r people behind the vehicle Drive slowly Avoid backing on inclines Avoid turning at sharp angles NOTE This Polaris ATV is equipped with a reverse speed limiter Do not operate at full throttle Use just...

Page 93: ...to be in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Operation of o...

Page 94: ...stem The emissions from the exhaust of this vehicle are controlled by engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris spe...

Page 95: ...e following pages A tool kit is provided in the storage compartment under the seat Keep the tool kit with the vehicle at all times Maintenance intervals in the following charts are based upon average...

Page 96: ...nded idle S Short trip cold weather operation Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available f...

Page 97: ...form these services Maintenance Chart Key Perform these procedures more frequently for vehicles subjected to severe use E Emission related service Failure to conduct this maintenance will not void the...

Page 98: ...re Ride Inspect tighten Frame fasteners Pre Ride Inspect tighten E Air filter and Pre cleaner Pre Ride Inspect clean replace as needed Coolant Pre Ride Inspect level add as needed Fuel Pre Ride Fill t...

Page 99: ...rease to connector when replaced Tail lamp brake lamp Pre Ride Check daily A arm ball joint Pre Ride Check freeplay daily have dealer replace if wheel moves excessively Rear shaft assembly Pre Ride Po...

Page 100: ...eeded J Brake pad wear 10 H Monthly 100 160 Inspect periodically Oil Change 10 H 6 M 100 160 Perform break in service after first hour of operation Oil Filter 10 H 6 M 100 160 Replace with oil change...

Page 101: ...00 Inspect adjust replace if necessary E Choke enricher cable 50 H 6 M 500 800 Inspect adjust lubricate replace if neces sary Drive chain s 50 H 6 M 500 800 Inspect daily adjust and lubricate if neede...

Page 102: ...driving in water F Front A Arms B 50 H 3 M 500 800 Inspect tighten fasteners grease also after washing ATV or driving in water F Rear Control Arm Bushings C 50 H 3 M 500 800 Inspect tighten fasteners...

Page 103: ...0 1600 Pressure test system annually E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed J E Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve pump and carburetor r...

Page 104: ...ake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out J Front and rear wheel bearings 300 H 36 M 3000 4800 Inspect replace as needed Idle speed As require...

Page 105: ...de the ultimate in lubrication performance and protection and prolonged clutch life See page 183 for the part numbers of Polaris products PS 4 oil possesses unsurpassed film strength over the widest p...

Page 106: ...ne and let it idle for one minute 3 Stop the engine and remove the dipstick Wipe it dry with a clean cloth 4 Reinstall the dipstick completely NOTE The dipstick must be screwed completely in to keep t...

Page 107: ...oil level frequently A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the oil tank Water in the bottom of the tank can lead to engine d...

Page 108: ...t oil and filter overnight Always replace the oil and filter within a few hours of draining the oil Always change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page...

Page 109: ...utes until warm then stop the engine 4 Place a drain pan beneath the oil tank and remove the drain plug CAUTION Hot oil can cause serious burns to skin Do not allow hot oil to contact skin 5 Allow the...

Page 110: ...g washer and reinstall the plug Torque to 14 ft lbs 19 Nm 10 Place shop towels beneath the oil filter 11 Remove the three cover bolts and remove the cover 12 Pull out the oil filter NOTE A spring loca...

Page 111: ...ricate the gasket on the new filter with a film of fresh engine oil 16 Reinstall the spring and install the new filter with the open end facing outward 17 Install the cover and torque the bolts to 72...

Page 112: ...ce the transmission in neutral Lock the parking brake 20 Prime the oil pump using the procedure on page 110 Then stop the engine and inspect for leaks 21 Re check the oil level on the dipstick and add...

Page 113: ...lamp or pinch off the vent line 1 approximately 2I 5 cm from the oil tank 2 Run the engine for 5 10 seconds at idle Stop the engine and remove the vent line clamp If the line is bled properly you shou...

Page 114: ...d that you completely drain the cooling system every two years and add a fresh mixture of antifreeze and water Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixtur...

Page 115: ...g temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting coo...

Page 116: ...en drained for maintenance and or repair However if the recovery bottle has run dry inspect the level in the radiator and add coolant if necessary The radiator pressure cap is located on the left side...

Page 117: ...nd rotate the cover rearward to remove it 3 Remove the air filter retaining screw 2 4 Loosen the filter clamp 3 5 Remove the main air filter 4 6 Remove the pre filter 5 from the main filter element 7...

Page 118: ...nd let dry 10 Apply a commercially available foam filter lubricant to the foam filter 11 Reinstall all components 12 Check the hoses for cracks deterioration abrasion or leaks Replace as needed CAUTIO...

Page 119: ...t spot that will shorten the life of the lamp WARNING Poor lighting while driving can result in severe injury or death Headlight and taillight lenses become dirty during normal operation Wash the head...

Page 120: ...he bulb housing and turn it counterclockwise 1 to remove the bulb On the right headlamp turn the bulb housing clockwise 2 to remove the bulb 3 Apply dielectric grease to the socket and install the new...

Page 121: ...in the hole of the mounting tab on the cab 6 Install the adjuster bracket onto the inboard pivot pin of the headlamp Adjust for approximately 1 16 clearance between the bracket and the edge of the hea...

Page 122: ...t and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam shoul...

Page 123: ...off with each movement of the brake pedal 3 If the light does not operate properly grasp the switch body 1 with a pliers or similar tool and hold it lightly but securely Using a wrench rotate the adju...

Page 124: ...the left fender 3 Remove the fuel tank cover screws 2 4 Remove the four side panel screws 3 5 Gently pull the cab upward to disengage it from the stand off Place the cab upside down on a soft protecti...

Page 125: ...E AND LUBRICATION Rear Cab Removal 1 Unlatch and remove the seat 2 Remove the two lower bolts 1 on the rear fenders of the cab and the two bolts 2 washers and grommets 3 on the top of the cab 3 Remove...

Page 126: ...rranty Always use Polaris recommended spark plugs Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the...

Page 127: ...TE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is bla...

Page 128: ...ls and front cab see page 121 2 Turn the fuel valve off WARNING A hot ember on the ATV could cause fuel to ignite Allow all components to cool sufficiently before accessing the spark plug Always exerc...

Page 129: ...Plug Removal and Replacement 3 Move the fuel valve hose clamp 1 forward and gently remove the hose from the fuel valve fitting on the gas tank 4 Remove the vent hose 2 from the steering post taking n...

Page 130: ...rotect the valve from contamination or damage 7 Using the forked end of the spark plug wrench handle remove the spark plug boot IMPORTANT Do not pull on the wire to remove the boot Doing so may cause...

Page 131: ...gine has been run as the exhaust system becomes very hot Serious burns could result from contact with the exhaust components Wear eye protection and gloves Never run the engine in an enclosed area Exh...

Page 132: ...Arrestor 1 Remove the three screws 1 and remove the arrestor 2 from the end of the muffler 2 Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if components are warm...

Page 133: ...he end of the muffler 2 Use a non synthetic brush to clean the arrestor screen 3 A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspec...

Page 134: ...depth Serious engine damage WILL occur Tow or trailer the ATV to your dealer for service In an emergency perform the temporary drying out procedure outlined below which will allow short term operation...

Page 135: ...bout 10 seconds 4 Remove the spark plug See page 125 WARNING Fluids will be ejected through the spark plug hole and may cause serious injury to face or other body parts Stand clear of the spark plug w...

Page 136: ...water has entered the oil tank Do not start the engine Tow the ATV and see your dealer If the oil level is unchanged from the pre ride inspection level replace the spark plug start the engine and mov...

Page 137: ...remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with d...

Page 138: ...be removed and stored out of the sun in a cool dry place Test and recharge the battery monthly and before reusing Battery Removal 1 Remove the front cab see page 121 and disconnect the strap securing...

Page 139: ...tighten the black negative cable 3 Attach the hold down strap and reinstall the front cab 4 Verify that cables are properly routed NOTE When installing a new battery make sure it s fully charged prior...

Page 140: ...e A fully charged battery will register 12 8 V or higher If the voltage is less than 12 8 volts recharge the battery Use the remote charging terminals under the right front cab Removing the cab is not...

Page 141: ...ufacturer s instructions for recharging When using a constant current charger use the guidelines on the following page for recharging WARNING An overheated battery could explode causing severe injury...

Page 142: ...andard 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 month...

Page 143: ...will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the ATV decal and in the owner s manual Always use original...

Page 144: ...to 1 8 3 mm or less See illustration Wheel Removal 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by pl...

Page 145: ...em to the inside of the vehicle Always ensure that all nuts are torqued to specification 1 Place the transmission in gear and lock the parking brake 2 Place the wheel on the wheel hub with the valve s...

Page 146: ...TION Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Torque Specification Front 3 8 30 35 ft lbs 40 47 Nm Rear...

Page 147: ...re operating the vehicle If a boot is torn punctured or leaking fluid see your Polaris dealer for service or replacement Good Boot After Operating Inspect the boots after operating the vehicle If a bo...

Page 148: ...y tools that may damage the boot 2 Slide the free end of the boot two inches toward the center of the vehicle and lift the boot away from the shaft to allow excess air to escape 3 Wipe excess grease f...

Page 149: ...front brakes are hydraulic disc brakes They re activated by squeezing the brake lever toward the handlebar The rear brake is a hydraulic disc brake activated by the foot brake pedal Both brakes are se...

Page 150: ...uid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness 5 Check the security and surface condition of the disc 6 Inspect the rear brake...

Page 151: ...rized Polaris dealer Toe Alignment Use the following procedure to check toe alignment The vehicle is designed for a neutral toe setting 1 Position the vehicle on a level surface 2 Place the handlebars...

Page 152: ...etween the string in front of the rear tires A and in front of the front tires B If the two measurements are not equal adjust the string position until the measurements are equal 6 Measure the distanc...

Page 153: ...ck the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the chain At the center point of the top side of the chain there should be 1 4 3 8 6 9 mm deflect...

Page 154: ...unting bolts 1 2 Thread the chain adjusting bolt 2 inward or outward to adjust chain slack to the proper dimension 3 Tighten the pivot mounting bolts to 30 ft lbs 40 Nm 4 Torque the chain adjusting bo...

Page 155: ...oss of control and serious injury or death Follow the adjustment procedures exactly or see your Polaris dealer for service 1 Loosen the four handlebar bolts 1 2 Adjust the handlebar to the desired hei...

Page 156: ...should be checked periodically for loose nuts and bolts If loose nuts and bolts are found or if you notice any freeplay in the steering post see your Polaris dealer for service before operating the v...

Page 157: ...lacing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance from the ground to the bottom of the low...

Page 158: ...to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 9 Subtract the step 8 measurement from the step 4 measurement The difference should be between 3...

Page 159: ...to suit different riding conditions and operator weight WARNING Uneven adjustment may cause poor handling of the ATV which could result in an accident and serious injury or death Always adjust both th...

Page 160: ...ring Preload 1 Raise and safely support the front of the ATV off the ground to allow the suspension to fully extend 2 Turn the adjusting ring 1 clockwise to increase preload A Turn the ring counter cl...

Page 161: ...ne 3 Elevate the rear of the vehicle by placing a suitable stand under the frame NOTE The tires should be barely touching the ground and the suspension should be at full rebound 4 Measure the distance...

Page 162: ...uspension 7 Turn the handlebars fully to the left and right 8 With the rider still on the vehicle repeat the measurement performed in step 4 9 Subtract the step 8 measurement from the step 4 measureme...

Page 163: ...ockwise until it stops the damping is in the softest position position 1 Turn the screw clockwise to increase damping NOTE Use a flat blade screwdriver to make damping adjustments Rear Shock Setting C...

Page 164: ...ping may be adjusted to suit different riding conditions and operator weight Spring Preload 1 Raise and safely support the rear of the ATV off the ground to allow the suspension to fully extend 2 Turn...

Page 165: ...of the shocks on the lower clevis Use a screwdriver to make adjustments To set the shock at the softest setting position 1 turn the screw counter clockwise until it stops From this position turn the...

Page 166: ...w B and lock ring C 3 Loosen the lock ring and turn the screw in clockwise to increase lever travel Turn the screw out counterclockwise to decrease lever travel Tighten the lock ring 4 Squeeze the lev...

Page 167: ...s who perform this procedure must follow the adjustment procedures exactly Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 and loosen th...

Page 168: ...m up the engine by running the vehicle for five minutes or until operating temperature is reached 2 Apply the parking brake and place the transmission in neutral 3 Adjust the carburetor idle screw 1 e...

Page 169: ...ation and driveability Above 6000 feet 1800 m the engine air fuel mixture becomes overly rich An engine loses approximately 3 of its power for each 1000 foot 305 m increase in elevation Although this...

Page 170: ...also extend the life of various components CAUTION High water pressure may damage components Polaris recommends washing the vehicle by hand or with a garden hose using mild soap Certain products incl...

Page 171: ...wer parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips S Avoid the use of harsh cleaners which can scratch the finish S Do not use a power...

Page 172: ...s Avoid directing the water stream at the following items S Wheel bearings S Transmission seals S Brakes S Cab and body panels S Labels and decals NOTE If warning and safety labels are damaged contact...

Page 173: ...the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips S Avoid the use of automotive products some of which can scratch the finish of your ve hicle S Always use cl...

Page 174: ...page 167 Stabilize the Fuel Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer to the fuel tank following the instructions on the container for the recommended amount Fill the fuel tan...

Page 175: ...replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter Inspect and clean or replace the breather filter inside the airbox Fluid Levels Inspect all fluid...

Page 176: ...seat 3 Loosen the intake duct clamp at the carburetor and pull the duct off the carburetor 4 Start the engine and spray Polaris fogging oil or a comparable product into the carburetor following the i...

Page 177: ...son Grease Engine Anti Freeze Test engine coolant strength and add or change coolant if necessary Replace coolant every two years Storage Area Covers Set the tire pressure and safely support the ATV w...

Page 178: ...the key to prevent loss during transporting 2 Turn the fuel valve off 3 Be sure the fuel cap oil cap and seat are installed correctly 4 Always tie the frame of the ATV to the transporting unit securel...

Page 179: ...s using the following charts Engine Doesn t Turn Over Possible Cause Solution Fuseable link See Polaris dealer for replacement Low battery voltage Recharge battery to 12 8 VDC Loose battery connection...

Page 180: ...is turned off Turn the fuel valve on Old poor or non recommended fuel Drain and replace with new fuel Fouled or defective spark plug Inspect plug s replace if necessary No spark to spark plug Inspect...

Page 181: ...to specs or replace plugs Engine Backfires Possible Cause Solution Weak fouled or defective spark plug Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs...

Page 182: ...cs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC or replace Kinked or plugg...

Page 183: ...on recommended fuel Replace with recommended fuel Clogged fuel valve screen See your Polaris dealer Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of choke...

Page 184: ...e Inspect clean and or replace spark plugs Fouled or defective spark plug Inspect clean and or replace spark plugs Worn or defective spark plug wire See your Polaris dealer Incorrect spark plug gap or...

Page 185: ...echanical failure See your Polaris dealer Overheated engine Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Engine Overheating Possible Cause Solution Debris l...

Page 186: ...Gun Kit Premium All Season 3 oz Additives Miscellaneous 2871322 Premium All Season Grease 3 oz cartridge 2871326 Carbon Clean Plus 12 oz 2871423 Premium All Season Grease 14 oz cartridge 2870652 Fuel...

Page 187: ...utput 200 w 3000 RPM Wheelbase 51 in 130 cm Compression Ratio 10 8 1 Ground Clearance 11 5 in 29 cm Starting System Electric Dry Weight 439 lbs 199 kg Carburetor BSR 42mm Minimum Turning Radius 67 in...

Page 188: ...sc Gear Ratio 1st 2 429 Rear Brake Hydraulic Disc Gear Ratio 2nd 1 611 Parking Brake Hydraulic lock front wheel Gear Ratio 3rd 1 286 Headlights 2 Dual Beam 35w 35w Gear Ratio 4th 1 087 Taillights LED...

Page 189: ...laris 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 re...

Page 190: ...osion or defects in parts components or the ATV 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...

Page 191: ...OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Som...

Page 192: ...istance they will contact the appropriate personnel 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 above terms...

Page 193: ...have received authorization for export from Polaris Industries Dealers may not give authorization for export You should consult an authorized dealer to determine this vehicle s warran ty or service bu...

Page 194: ...ve hicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification th...

Page 195: ...ed outside of the country where it was purchased and you have not followed the proce dure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind Ve...

Page 196: ...ranty period for this vehicle begins on the date the vehicle is delivered to the original retail pur chaser and ends 30 months 2 5 years after that date or after 5000 km 3100 miles whichever comes fir...

Page 197: ...TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied war ranty lasts so the above...

Page 198: ...INTENANCE LOG Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 1...

Page 199: ...196 MAINTENANCE LOG Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 200: ...197 MAINTENANCE LOG Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks...

Page 201: ...Coolant Level Recovery Bottle 112 Cooling System 111 112 Crankcase Emission Control 91 D Driving Across Hills 80 Driving Downhill 81 Driving in Reverse 88 89 Driving on Slippery Surfaces 78 Driving O...

Page 202: ...Gear 12 13 Safety Decals and Locations 8 11 Safety Training 15 Shift Pedal 63 Shifting Gears 64 Side Panel Removal 121 Spark Arrestor Clean Out 128 130 Spark Plugs 123 127 Specifications 184 185 Sprin...

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