Polaris 2007 Predator 50 Owner'S Manual Download | Manualshive

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133

Maintenance

CVT Drying

There may be some instances when water is accidently ingested into the CVT system. Use

the following instructions to dry it out before operating. The drain plug is located on the bot-

tom of the CVT cover.
1. Remove the drain plug. Allow the water to drain. Reinstall the drain plug.
2. Start the engine. Apply varying throttle for 10-15 seconds to expel the moisture and air-

dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

3. Allow the engine RPM to settle to idle speed.
4. Test for belt slippage. If the belt slips, repeat the process.
5. Take the vehicle to your dealer for service as soon as possible.

CAUTION

Exposure to salt water will cause corrosion to metal components. If your vehicle is operated in salt

water areas, rinse it off frequently with fresh water.

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Summary of Contents for 2007 Predator 50

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Page 3: ...r 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 WARNING The engine exhaust from this product contains chemicals known to...

Page 4: ...1 Visit us at www polarisindustries com...

Page 5: ...d 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 publication are...

Page 6: ...ldren differ in skills physical abilities and judgement Some children may not be able to operate an ATV safely Always supervise your child s use of the ATV and permit continued use only if you determi...

Page 7: ...the information in your owner s manual Ask your parents to explain anything you don t understand and pay close attention to the warnings and instructions you read Your safety and the safety of others...

Page 8: ...ecals 34 Driver Warnings 41 Vehicle ID Numbers 64 Features and Controls 65 Break in Period 82 Pre Ride Inspections 84 Starting the Engine 87 Stopping the Engine 90 Driving Safely 91 Emission Control 1...

Page 9: ...roved ATV safety training course such as the SVIA RiderCoursesm and understand all warnings and the owner s manual before driving the ATV Know Your ATV Before Riding Parents must help their children l...

Page 10: ...and your age eligible family members who will be riding the ATV to take the ATV RiderCoursesm In addition you were provided with printed material and a video or DVD that instructs oper ators on safe...

Page 11: ...on your vehicle or in this manual alerts you to the potential for injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety ale...

Page 12: ...us to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills...

Page 13: ...hicle Y 12 90cc models are designed for children not less than 12 years of age and Y 6 50cc models are designed for children not less than 6 years of age No child under the age of 16 should ride any A...

Page 14: ...your experience Never attempt jumps or other stunts Never tow or pull an object behind the ATV Always inspect your ATV each time you use it to make sure it is in safe operating condition Always follow...

Page 15: ...limbing hills as described in this manual Check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open th...

Page 16: ...p hill Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special...

Page 17: ...rns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them lightly several times to let friction dry...

Page 18: ...oses Any modifications to the original equipment of the vehicle create a substan tial safety hazard and increase the risk of bodily injury The warranty on your Polaris ATV is terminated if any equipme...

Page 19: ...16...

Page 20: ...17 Youth Section...

Page 21: ...ifications section beginning on page 172 for your ATV s capacity CHILDREN Before you ride your new Polaris ATV there are some important things that you need to know Your safety and the safety of other...

Page 22: ...to shut the engine off quickly The button must be up before you can start the engine again 2 Horn Button Press the horn button to sound the horn 3 Throttle Control Press the throttle lever with your t...

Page 23: ...er If your battery is too weak to start your ATV you can push down on the kick start lever with your foot to start the engine Have an adult show you how it works Read more about how to use the kick st...

Page 24: ...have an adult put gas in your ATV Never try to do it yourself 6 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the...

Page 25: ...s the rear brake The right lever controls the front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and b...

Page 26: ...trap must always be attached snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never rid...

Page 27: ...24 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off...

Page 28: ...t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close t...

Page 29: ...e your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride with sticky brakes Have an adult or your Polaris dealer fix the sticky brakes before you...

Page 30: ...heck the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks n This last check is done with the engine running You must check to make sure that all...

Page 31: ...riving an ATV Adults have riding rules too The rules help keep us safe when we ride X The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always d...

Page 32: ...s to protect your hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy boots to keep your feet dry Boots will also protect your feet and ankles from...

Page 33: ...he ATV harder to drive You may lose control and hurt yourself and your passenger X Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests X Alwa...

Page 34: ...ght Your ATV doesn t have lights that are safe for driving in the dark X Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them X Never ride on frozen water You...

Page 35: ...32 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new Polaris ATV...

Page 36: ...33 Adult Section...

Page 37: ...any of the decals shown 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 contact your Pola...

Page 38: ...for your skills or the conditions on public roads a colli sion can occur with another vehicle with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use pro...

Page 39: ...hich could result in severe injury or death Adult supervision is required Make sure operators follow Owner s Manual and labels Make sure operators watch the safety video or DVD and complete the ATV Ri...

Page 40: ...arning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 3 20 7 REAR 3 20 7 MAXIMUM WEIGHT CAPACITY INCLUDING D...

Page 41: ...38 Safety Decals No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH...

Page 42: ...lt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause part failure possib...

Page 43: ...40...

Page 44: ...o read all of the following warnings about driving hazards and how to avoid them These warnings are provided for your child s safety Be sure to explain to your young driver that the following hazards...

Page 45: ...ations 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 regula...

Page 46: ...commended for their age can lead to severe injury or death of the child Even though a child may be within the age group for which some ATVs are recommended he or she may not have the skills abilities...

Page 47: ...duces your ability to balance and control this ATV Carrying a passenger could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpo...

Page 48: ...HAT CAN HAPPEN The ATV tires are designed for off road use 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 HAZARD Av...

Page 49: ...ublic streets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any paved or unpaved public street road or highway In many states...

Page 50: ...t increases the risk of a severe head injury or death in the event of an acci dent Operating without eye protection and protective clothing can also result in injury HOW TO AVOID THE HAZARD Always wea...

Page 51: ...onsuming alcohol or drugs WHAT CAN HAPPEN Your judgment could be seriously affected You may react more slowly Your balance and perception will be affected You could have an accident HOW TO AVOID THE H...

Page 52: ...visibility and operating conditions and your experience WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Increases the possibil...

Page 53: ...L 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 stunts Avoid...

Page 54: ...foot can make it harder to control the ATV or could cause you to lose your balance and fall off the ATV If you remove a foot from the footrest your foot or leg may touch the rear wheels which could i...

Page 55: ...in WHAT CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react This could cause the ATV to overturn or go out of control HOW TO AVOID THE HAZARD Go slowly and be extra c...

Page 56: ...sively 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 slipper...

Page 57: ...n the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed WARNING POTENTIAL HAZARD Towing or pulling an object behind the ATV WHAT C...

Page 58: ...lls as described in the Owner s Manual beginning on page 98 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your wei...

Page 59: ...ocedures for going down hills as described in the Owner s Manual See page 104 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start d...

Page 60: ...urn 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 102 Use extra caution when turning on any hill Avoid crossing the...

Page 61: ...es gradually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If you begin rolling backwards Keep weight uphill Never apply engine power Never app...

Page 62: ...ra caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating over obstacles WHAT CAN HAPPEN Operating over obstacles could cause loss of control...

Page 63: ...WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Use of improper tires or operation of the ATV with improper or uneven tire pre...

Page 64: ...ough deep or fast flowing water If it s unavoidable to enter water that exceeds the recommended maximum depth see page 106 travel slowly balance your weight carefully avoid sudden movements and mainta...

Page 65: ...WARNING POTENTIAL HAZARD Operating the ATV with improper modifica tions WHAT CAN HAPPEN Improper installation of accessories or modifi cation of the ATV may cause changes in han dling which could lea...

Page 66: ...alified ser vice dealer check the complete vehicle includ ing but not limited to brakes throttle and steering for possible damage WARNING Hot components can cause serious burns Do not touch hot exhaus...

Page 67: ...existing keys The igni tion switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame Identification Number ________...

Page 68: ...the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle res...

Page 69: ...r emergency NOTE Both the main switch and the engine stop switch shut off all electrical power to the entire vehicle To stop the engine quickly push the stop switch down Choke Lever Use the choke to s...

Page 70: ...ar Engine Start Button The start button is located slightly above the choke lever 1 Attach the tether strap securely to the vehicle and to the rider s right wrist 2 Turn the key to the ON position 3 L...

Page 71: ...or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle syst...

Page 72: ...ned to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever the engine will stop and power to the rear whe...

Page 73: ...the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious i...

Page 74: ...release the parking brake lock squeeze and release the brake lever The parking brake will release automatically WARNING Operating the ATV while the parking brake is engaged could cause an accident re...

Page 75: ...always in forward gear Using the throttle to warm the engine will cause the vehicle to move forward if the parking brake is not locked Always lock the parking brake before starting the engine Always...

Page 76: ...equipped with lights that are designed for driving in the dark Do not operate this ATV after dark Use caution and drive at reduced speeds in conditions of reduced visi bility This ATV is designed for...

Page 77: ...flames or sparks in or near the area where refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately...

Page 78: ...nd Controls Fuel System WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm Operate this vehicle only outdoors or in well ven...

Page 79: ...el System Gas Cap The fuel tank filler cap is located directly below the handlebars Use unleaded gasoline with a minimum pump octane of 87 Refer to the specifications section beginning on page 172 for...

Page 80: ...torage and when transporting ON For normal operation RES For reserve supply if main supply is exhausted NOTE The reserve setting allows operation for approximately 7 10 miles 11 16 km Always refill th...

Page 81: ...and provide comfort for shorter operators An operator will also have better control of the ATV when both feet can remain firmly planted on either the footwells or the risers If the operator s legs are...

Page 82: ...1 Remove the rubber caps covering the screw access holes 2 Remove the screws and nuts securing the footwell riser to the footwell 3 Remove the riser 4 Reverse the procedure to reinstall the footwell r...

Page 83: ...tion the vehicle on a level surface 2 Lock the parking brake 3 Fold out the kick start lever on the left side of the vehicle 4 Push the engine stop switch up to the ON position 5 Turn the key to ON 6...

Page 84: ...m the under seat storage area 9 Remove the plug from the kick start access hole on the left side of the vehicle NOTE Store the plug in a secure location Always reinstall the access hole plug whenever...

Page 85: ...nt of a new engine will result in more efficient performance and longer life for the engine Per form the following procedures carefully CAUTION Excessive heat build up during the first three hours of...

Page 86: ...dling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 84 6 Perform t...

Page 87: ...t the ATV before each use to ensure it s in proper operating condition Pre Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 141 145 Front suspension Inspect lubricate...

Page 88: ...nsure fastener tightness check that axle nuts are secured by cotter pins 157 157 Fuel and oil Check and fill as needed 74 76 Throttle Check for proper operation 25 68 69 Engine stop switch Check for p...

Page 89: ...lean or replace 152 Drive chain Check condition and slack refer to drive chain adjustment 149 Frame nuts bolts fasteners Inspect ensure tightness Loose or damaged components Visually inspect for any d...

Page 90: ...on monoxide and can cause loss of consciousness result ing in severe injury or death Never run an engine in an enclosed area CAUTION Operating the ATV immediately after starting could cause engine dam...

Page 91: ...cold use full choke by pushing the choke lever all the way to the left Do not use the choke when starting a warm engine NOTE The choke is fully on when the lever is pushed completely to the left The c...

Page 92: ...e to start 9 Activate the starter for a maximum of five seconds releasing the button when the engine starts If it doesn t start release the starter wait five seconds then activate for another five sec...

Page 93: ...here are three ways to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV NOTE To avoid draining the battery always turn the key to the OFF position wh...

Page 94: ...ets 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 ECE 22 05 labe...

Page 95: ...rsonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and...

Page 96: ...arking brake 3 Start the engine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Slowly squeeze and release the left brake lever 6 Slowly press the throttle with y...

Page 97: ...ction 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 trac...

Page 98: ...r rain you re traveling on Be constantly alert for hazards such as logs rocks and low hang ing branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacl...

Page 99: ...e care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on exc...

Page 100: ...vel or during freezing weather follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause s...

Page 101: ...when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operati...

Page 102: ...travel straight uphill 2 Avoid steep hills 15 maximum 3 Keep both feet on the footrests 4 Transfer your weight forward 5 Proceed at a steady rate of speed and throttle opening 6 Remain alert and be pr...

Page 103: ...ARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper...

Page 104: ...tion where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keep ing your feet on the footrests 3 Steer slightly into...

Page 105: ...weight uphill 2 Shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill WARNING Improper hill climbing procedures could cause loss of...

Page 106: ...rake allowing the ATV to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the ATV from the uphill side keeping body weight uphill...

Page 107: ...irectly downhill 2 Transfer your weight to the rear of the vehicle 3 Slow down 4 Apply the front and rear brakes at the same time and very slightly to aid in slowing WARNING Excessive speed can cause...

Page 108: ...Avoid parking on a hill or incline if pos sible If it s unavoidable follow these precautions 1 Turn the engine off 2 Lock the parking brake 3 Always block the rear wheels on the downhill side as shown...

Page 109: ...water 1 Determine water depths before driving through water 2 If crossing a stream choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4...

Page 110: ...nance chart beginning on page 110 The following areas need special attention engine oil gearcase oil front and rear gearcases if equipped and all grease fittings CAUTION Major engine damage can resul...

Page 111: ...e USDA Forest Service Standard 5100 1C Federal law requires that this spark arres tor be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public...

Page 112: ...at the operator perform Any other adjustments should be performed by an authorized Polaris dealer The emissions label is located on the clutch cover or engine case near the clutch box NOTE The install...

Page 113: ...tment under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe...

Page 114: ...rts available from your Polaris dealer NOTE Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer perform these operations Sev...

Page 115: ...on from grease fittings and other critical components E Emission related service Failure to conduct this maintenance will not void the emis sions warranty but may affect emissions Q Dealer service ite...

Page 116: ...the Pre Ride Check list 84 Front suspension Daily Rear suspension Daily Tires Daily Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily Engine oil level Daily E A...

Page 117: ...t and lubricate if needed 149 CVT housing if equipped Weekly Drain water as needed check often if operating in wet conditions 133 Break in Maintenance After first 10 hours of operation Perform break i...

Page 118: ...filter screen 40 12 M 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours 123 X General lubrication 50 3 M 500 800 Lubricate all fittings pivots cables etc QE...

Page 119: ...r air intake ducts flange 50 6 M 500 800 Check for proper sealing air leaks Q Drive belt 50 6 M 500 800 See your Polaris dealer XQ Brake pad wear 50 6 M 500 800 See your Polaris dealer QE Fuel system...

Page 120: ...ect for wear routing security apply dielectric grease to connec tors subjected to water mud etc Q Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 1...

Page 121: ...c Youth Oil or Synthetic SAE 40 See page 120 Gearcase Transmission Oil Level Premium AGL Synthetic Gearcase Lube See page 126 Drive Chain Polaris Chain Lube or SAE 80 90 See page 149 X Front Suspensio...

Page 122: ...119 Maintenance Lubrication Guide Grease Points Grease Points...

Page 123: ...not use automotive oil See page 174 for the part numbers of Polaris products Under These Operating Conditions Use This Recommended Oil Outside air temperature is above 32 F 0 C Polaris Synthetic Yout...

Page 124: ...an cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level NOTE A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moist...

Page 125: ...vehicle on a level surface 2 Clean the area around the pre filter plug 3 Start the engine Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause serious burns to skin Do...

Page 126: ...tely 7 Wash the oil pre filter screen with solvent to remove debris Allow the screen to air dry 8 Clean the pre filter plug Install a new sealing washer on the plug NOTE The sealing surfaces on the pl...

Page 127: ...ended oil Do not overfill NOTE See the specifications section beginning on page 172 for capacities 12 Reinstall the dipstick 13 Start the engine Allow it to idle for one to two minutes 14 Stop the eng...

Page 128: ...The Polaris ATV is equipped with an in line fuel filter This filter should be replaced by your dealer at the intervals recommended in the Periodic Maintenance Chart beginning on page 110 Do not attem...

Page 129: ...hange the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 110 Polaris recommends the use of AGL Synthetic Gearcase Lubricant See page 174 for the part numbers of Pola...

Page 130: ...rcase 4 Remove the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fil...

Page 131: ...dition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color CAUTION Using non recommended spark plugs...

Page 132: ...tor throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are...

Page 133: ...starting it follow the steps outlined below 1 Move the ATV to dry land or at the very least to water below the footrests 2 Turn the fuel valve off 3 Check the air box for any water and dry it if wate...

Page 134: ...e it with a new plug 8 Tighten the carburetor drain screw 9 Turn the fuel valve on 10 Attempt to start the engine If necessary repeat the drying procedure 11 Take the ATV to your dealer for service as...

Page 135: ...ration and additional loads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the...

Page 136: ...art the engine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 3 Allow the engine RPM to se...

Page 137: ...beginning on page 110 WARNING Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrestor while the system is hot Allow components to cool suf...

Page 138: ...ynthetic brush to clean the arrestor screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with com pressed air 3 Inspect the screen for wear and damage Rep...

Page 139: ...h 1000 foot 304 8 m increase in elevation Although this power cannot be regained adjustments to the carburetor and drive system can be made to allow more efficient operation Optional jets available fr...

Page 140: ...rbure tor can be adjusted 1 Start the engine 2 Lock the parking brake 3 Allow the engine to run for approximately five minutes 4 Adjust the carburetor idle screw either in or out until the desired idl...

Page 141: ...either prior to the sale or later even at the consumer s request remove or adjust any speed limiting devices Your Polaris ATV has an adjustable throttle limiting screw Speed limiting devices may be ad...

Page 142: ...ottle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten th...

Page 143: ...le for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay fa...

Page 144: ...the intervals rec ommended in the Periodic Maintenance Chart beginning on page 110 If the freeplay isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay Specific...

Page 145: ...icle by placing a suitable stand under the frame The front tires should be slightly off the ground 3 While rotating the left front wheel tighten the upper front brake adjuster nut on the right hand co...

Page 146: ...ront brake adjuster nut on the right hand control 6 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 7 Verify that the right hand brake functions correctly...

Page 147: ...be slightly off the ground 3 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 4 When you begin to feel a slight drag in wheel rota tion loosen the wing nut one fu...

Page 148: ...on the preceding pages use the following information to determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table...

Page 149: ...eering frog can be 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 vehicle perpendicular to...

Page 150: ...on each side of the vehicle and goes around the stands in front of the vehicle 4 Measure the distance from the string to the rim at the front and rear of the front rim Rear mea surement should be 1 1...

Page 151: ...und have your dealer tighten them before operating the ATV Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The rear shock absorber springs are adjustable to increase...

Page 152: ...wet conditions See page 174 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t use...

Page 153: ...e amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain 2 The chain should have 1 4 1 2 6 12 mm deflection If the chain needs adjustment use the proce...

Page 154: ...nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft lbs 25 Nm 5 Tighten the four rear housing mount bolts to 43 ft lbs 60 Nm CAUTION Ho...

Page 155: ...ps and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply a commercially available...

Page 156: ...or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat CAUTION Never operate the ATV with the filter element removed Dirt will enter the engine cau...

Page 157: ...icle when turned fully to the left or right 3 Lightly tighten each bolt equally to prevent uneven gaps in the block Torque the bolts to 7 3 ft lbs 10 Nm WARNING Improper adjustment of the handlebars o...

Page 158: ...vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your ATV and in the owner s manual Always use original equi...

Page 159: ...worn to 1 8 3 mm or less Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest...

Page 160: ...tation 3 Install the wheel bolts and finger tighten them 4 Lower the vehicle to the ground 5 Securely tighten the bolts to 22 ft lbs 30 Nm Axle and Wheel Nuts All nuts with a cotter pin installed must...

Page 161: ...doesn t work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the lamp and replace it with a new recommended lamp 3 Test the light for p...

Page 162: ...ight assembly 3 Press the lamp retainer inward and turn it counter clockwise to remove it Note the posi tion of the lamp positioning tab then carefully pull the lamp out 4 Install the new lamp Make su...

Page 163: ...ire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly...

Page 164: ...vehicle 2 Remove the mounting bracket and battery 3 Disconnect the black negative battery cable first Disconnect the red positive battery cable last 4 Loosen the two nuts securing the battery plate to...

Page 165: ...to retain the battery in the mounting bracket 3 Connect and tighten the red cable first Connect and tighten the black cable last Torque the battery terminal bolts to 3 5 ft lbs 4 7 Nm 4 Install the mo...

Page 166: ...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 including insect rep...

Page 167: ...lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power w...

Page 168: ...the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring NOTE If warning and safety labels are d...

Page 169: ...sh on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehi cle Always use clean cloths an...

Page 170: ...he vehicle as recommended See page 163 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each mon...

Page 171: ...period 1 Fill the fuel tank 2 Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer Follow the instruc tions on the container for the recommended amount NOTE Carbon clean will also reduce...

Page 172: ...r Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sedi ment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Maintena...

Page 173: ...sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilated...

Page 174: ...Secure the fuel cap oil cap and seat 5 Turn the fuel valve off 6 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not off...

Page 175: ...4 Stroke Lubrication Wet Sump Oil Capacity 30 oz 900 ml Fuel Capacity 1 2 gallons 4 5 liters Fuel Reserve Capacity 22 gallons 85 liters Starting Electric with kick start backup Drive System Automatic...

Page 176: ...ke Mechanical Lock Front Tires 16 x 6 5 7 3 psi 20 7 KPa Rear Tires 16 x 8 7 3 psi 20 7 KPa Dry Weight 185 lbs 84 kg Length Width Height 48 122 cm 31 5 80 cm 28 71 cm Wheel Base 33 84 cm Ground Cleara...

Page 177: ...th Oil qt 95 l 2876249 Synthetic Youth Oil gal 3 8 l 2872175 Semi Synthetic 20W 40 Oil qt 95 l 2872176 Semi Synthetic 20W 40 Oil gal 3 8 l 2870791 Fogging Oil Aerosol Gearcase Transmission Lubricants...

Page 178: ...175 Polaris Products Part Number Description Grease 2871322 All Season Premium Grease 3 oz 89 ml 2871423 All Season Premium Grease 14 oz 414 ml Miscellaneous Additives 2871326 Carbon Clean Plus...

Page 179: ...system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spa...

Page 180: ...charger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octane fuel Replace with r...

Page 181: ...ugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with new fuel Incorrectly installed spark plug wires See your Polaris dealer Incorrect...

Page 182: ...e Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery with 5 amp charger Kin...

Page 183: ...el clean the fuel system Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect jetting See your Polaris dealer Possible Rich Fuel Mixture Cause Solution Overuse of...

Page 184: ...plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition conne...

Page 185: ...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 186: ...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 187: ...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 188: ...form warranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris This warra...

Page 189: ...s authorized location This policy does not apply to Safety Recalls How to Get Service In the country where your vehicle was purchased Warranty or Service Bulletin repairs must be done by an authorize...

Page 190: ...country If Purchased From A Private Party If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased all warranty coverage will be d...

Page 191: ...rements The emissions warranty 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 This emission related...

Page 192: ...N TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above l...

Page 193: ...to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED...

Page 194: ...191 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours...

Page 195: ...192 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 196: ...193 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 197: ...ing 133 CVT System 132 Cylinder Head Torque 130 D Daytime Running Lights 159 Drive Chain 149 Drive Chain Slack 150 Drive Chain Slack Adjustment 151 Driving Across Hillsides 100 101 Driving Downhill 10...

Page 198: ...ransmission 126 P Parking on a Hill or Incline 105 Periodic Maintenance Chart 110 117 Polaris Products 174 Polishing 166 Pre Ride Inspection 84 86 Product Safety Commission 14 R Riding Gear 91 92 S Sa...

Page 199: ...158 Tether Strap 23 Throttle 68 Throttle Cable Adjustment 140 Throttle Control 19 Throttle Lever 69 Throttle Stop Speed Control 139 Tire Tread Depth 156 Tires 155 Toe Alignment 146 147 Transmission Oi...

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