Polaris 2008 Outlaw 50 Owner'S Manual Download Page 154

Page: 154 / 199

151

Maintenance

Drive Chain Slack Adjustment

1. Loosen the four rear housing mount bolts.
2. Loosen the chain adjuster lock 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

Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud.

Housing

Mount

Bolts

Chain Adjuster

Summary of Contents for 2008 Outlaw 50

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Page 3: ...er 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 the State of California to cause cancer birth defects or other reproductive harm ...

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

Page 5: ...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 publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures con tained within whether whole or in part is ...

Page 6: ...ildren 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 determine that your child has the ability and maturity to operate the ATV safely Never allow a child to operate the ATV without adult supervision The preventive maintenance program outlined in this manual i...

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 is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re riding So read your manual and then enjoy r...

Page 8: ...Decals 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 108 Maintenance 110 Specifications 172 Polaris Products 174 Troubleshooting 176 Warranty 182 Maintenance Log 190 Index 194 ...

Page 9: ...proved 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 learn the proper and safe way to ride an ATV Read the owner s manual with your children before starting the engine for the first time and review it with them periodically afterwards ...

Page 10: ...u 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 operating procedures You should review this information with your child on a regular basis If you purchased a used Polaris ATV you can take the ATV RiderCoursesm by calling ATV Enrollment Express at ...

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 alert caution indicates a potential haz ard that may result in minor injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A note will ale...

Page 12: ...ous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precau tions Read and understand the owner s manual and all warnings before operating a Polaris ATV ...

Page 13: ...ehicle 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 ATV designed and sold for an adult Do not allow other children to ride this ATV unless they have read the manual seen the instructional video or DVD and taken and completed an approved ATV safety trai...

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 the inspection and maintenance procedures and sched ules described in this manual Always keep both hands on the handle bars and both feet on the footrests of the ATV during operation Always go slowl...

Page 15: ...climbing 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 the throttle suddenly or make sudden gear changes Never go over the top of any hill at high speed Always follow proper procedures for going down hills and for braking on hills as described in this manu...

Page 16: ...ep 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 procedure for braking described in this manual Dis mount on the uphill side or to either side if pointed straight uphill Turn the ATV around and remount following the proce dure described in this ma...

Page 17: ...urns 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 out the pads Always use the size and type of tires specified in this manual Always maintain proper tire pressure as described in this manual Never modify an ATV through improper installation or use ...

Page 18: ...poses 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 equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power NOTE The addition of certain accessories may change the handling characteristic...

Page 19: ...16 ...

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

Page 21: ...cifications 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 others is the most important thing to think about at all times As the driver of the ATV you must learn how to keep yourself and those around you safe while you re riding Pay attention when you see this sy...

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 thumb when you want the ATV to go forward Always make sure the throttle control does not stick before you drive your ATV Read more about it on page 25 3 Throttle Control 1 Engine Stop Switch 2 Horn Bu...

Page 23: ...ver 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 start on page 80 4 Kick Start Lever ...

Page 24: ...s 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 seat To replace the seat set it in place and push down on the seat above the latch Always make sure the seat is locked in place before riding 5 Gas Cap 6 Seat Latch ...

Page 25: ...ls 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 be seriously injured Always take your thumb off the throttle lever when you squeeze the brake levers 7 Rear Brakes 7 Front Brakes ...

Page 26: ...strap 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 ride without the tether strap attached to your right wrist and to your ATV Be careful not to let the cord get tangled around the handlebars or any part of your body 9 Tether Switch 8 Ignition Switch ...

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 to the handlebar the ATV has a sticky throttle This means that something is wrong or broken and must be fixed before you can ride your ATV safely Never start the engine if you have a sticky throttle Y...

Page 29: ...de 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 ride n Have an adult check to see if your ATV needs more gas Children must never add their own gasoline This must always be done by an adult Before anyone adds gasoline to your ATV they must read the...

Page 30: ...check 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 three ways to stop the engine of your ATV are working the way they should Do you remember what they are If you can t remember the three ways to stop the engine go back to page 24 and review Then hav...

Page 31: ...driving 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 drive safely Let s learn how to ride Always follow the safe riding rules found on the next pages You or others around you could be seriously hurt if you don t follow the safe riding rules ...

Page 32: ...es 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 scrapes and scratches Clothing Make sure your clothing fits properly If it s too small it could keep you from moving easily when you shift your weight If it s too big it could hang down and get caug...

Page 33: ...the 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 Always be alert and pay attention to where you re driving Pay attention to other drivers and be even more careful around them because you don t know what they re going to do X Never follow another ATV to...

Page 34: ...ight 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 could get hurt or you could even die All ice can be dan gerous X Ride your ATV only where you know it is safe to drive and where you have permission to drive Be careful of the things around you X Alw...

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 Polaris dealer to purchase a replacement Replacement safety decals are provided by Polaris at no charge The part num ber is printed on the decal ...

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 proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ...

Page 39: ...which 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 RiderCoursesm Never operate this ATV on HILLS steeper than 15 degrees 15 To prevent flipover on hilly terrain use throttle and brakes gradually ...

Page 40: ...Warning 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 DRIVER AND CARGO IS 90 LBS 41 KG ...

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: ...elt 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 possible imbalance and excessive engine RPM which can result in serious injury or death ...

Page 43: ...40 ...

Page 44: ...to 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 MUST be avoided at all times ...

Page 45: ...uations 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 regularly practice the skills learned in the course and the oper ating techniques described in the Owner s Manual For more information about the ATV RiderCoursesm contact ATV Enrollment Express at 800 887 ...

Page 46: ...ecommended 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 or judgment needed to operate the ATV safely and may be involved in a serious accident HOW TO AVOID THE HAZARD Follow the age recommendations for this ATV ...

Page 47: ...educes 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 purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for passengers ...

Page 48: ...WHAT 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 Avoid operating the ATV on pavement whenever possible If you must ride on a paved surface go slowly and do not make sudden turns or stops ...

Page 49: ...public 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 it is illegal to operate ATVs on public streets roads and highways ...

Page 50: ...et 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 wear an approved helmet that fits properly Always wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants ...

Page 51: ...consuming 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 HAZARD Never consume alcohol or drugs before or while driving this ATV ...

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 possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV each time you use it to make sure the ATV is in safe operating con dition Always follow the inspection and main ...

Page 53: ...AL 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 exhibition driving don t show off ...

Page 54: ...r 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 injure you or cause an accident HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of your ATV during opera tion ...

Page 55: ...ain 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 careful when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the ATV ...

Page 56: ...ssively 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 loose terrain until you ve learned and practiced the skills nec essary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain ...

Page 57: ...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 Towing or pulling an object behind the ATV WHAT CAN HAPPEN A wagon sled or other object towed behind an ATV does not have brakes or steering The object may overturn or collide with other objects and cause serious injuries HOW TO AVOID THE HAZARD Ne...

Page 58: ...ills 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 weight forward Never open the throttle suddenly The ATV could flip over backwards Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on the ot...

Page 59: ...rocedures 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 down any hill Shift your weight rearward Never go down a hill at high speed Avoid going down a hill at an angle which would cause the vehicle to lean sharply to one side Go straight down the hill when...

Page 60: ...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 102 Use extra caution when turning on any hill Avoid crossing the side of a steep hill When crossing the side of a hill Always follow proper procedures as described in the owner s manual Avoid hills with excessively slippery or loose surfaces Shift your weight to ...

Page 61: ...kes 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 apply the rear brake while rolling backwards Apply the front brake slowly When fully stopped apply rear brake as well and then lock the parking brake Dismount on uphill side or to either side if pointed...

Page 62: ...tra 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 or overturn HOW TO AVOID THE HAZARD Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees when possible If unavoidable use extreme cau...

Page 63: ...r 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 pressure could cause loss of control or accident HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the owner s manual for the ATV Always maintain proper tire pressure as stated ...

Page 64: ...rough 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 maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability Always test the brakes after leaving water I...

Page 65: ...d 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 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 Polaris Industries Inc...

Page 66: ...ualified 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 exhaust system components Hot components could cause a fire if exposed to combustible materials such as dry grass and weeds Always inspect the underside of the ATV after driving through tall grass weeds br...

Page 67: ...r existing keys The igni tion switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame Identification Number ________________________________________________________________ Engine Serial Number _____________________________________________________________________ Key Number on the key _____________________________...

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 resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Key ...

Page 69: ...er 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 start a cold engine Push the choke lever to the left before starting the engine When the engine starts gradually return the choke lever to the OFF position as the engine warms up and runs smoothly Sto...

Page 70: ...ear 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 Lock the parking brake 4 Push the engine stop switch up to the ON position 5 Press the start button ...

Page 71: ...t or operate an ATV with a sticking or improperly operating throttle Always contact your dealer for service if throttle problems arise Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation ...

Page 72: ...gned 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 wheels will cease WARNING The Electronic Throttle Control ETC 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 re...

Page 73: ...t 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 injury or death Always apply both brakes at the same time Rear Brakes Front Brakes ...

Page 74: ...o 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 resulting in serious injury or death It could also result in driveline or engine damage Always be sure to disengage the parking brake before operating the ATV Locked Not Locked ...

Page 75: ...s 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 lock the parking brake whenever the vehicle is left unattended ...

Page 76: ...t 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 off road use only Do not operate this ATV on streets or highways ...

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 wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a shor...

Page 78: ...and 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 ventilated areas ...

Page 79: ...uel 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 fuel tank capacity Gas Cap ...

Page 80: ...storage 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 the gas tank as soon as possible after using the main supply Always return the valve to the ON position after refueling OFF RES ON ...

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 long enough to comfortably reach the footwells without the risers the risers can be removed See the following page ...

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 riser for shorter operators Screw Cap Nut ...

Page 83: ...ition 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 Place your foot on the kick start then thrust your heel downward to crank the engine 7 After the engine has started fold the kick start lever back into place Kick Start Lever ...

Page 84: ...om 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 the kick start lever is removed from the vehicle 10 Install the kick start lever through the access hole ...

Page 85: ...ent 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 operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Mixing brands or using a non recommended oil ma...

Page 86: ...ndling 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 the following maintenance at the end of the break in period Item Remarks See Page Engine oil change Perform break in oil change 122 Oil pre filter screen Clean filter with oil change 123 Transmission ...

Page 87: ...ct 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 if necessary 118 Rear suspension Inspect lubricate if necessary 118 Steering Ensure free operation lubricate if neces sary 146 148 ...

Page 88: ...ensure 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 proper function 66 Daytime running lights if equipped Check for proper operation 159 Brakelight Check for proper operation 158 ...

Page 89: ...clean 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 damaged components or loose fasteners Riding gear Wear helmet goggles protective clothing 91 ...

Page 90: ...bon 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 damage Allow the engine to warm up for several minutes before operating ...

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 choke is off when the lever is pushed completely to the right The choke can be adjusted gradually depending on how much choke is needed for starting Full Choke Choke Off ...

Page 92: ...ne 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 seconds Repeat until the engine starts 10 If the engine slows or stops position the choke lever half way to allow proper engine warm up Vary the RPM slightly with the throttle to aid in warm up 11 When ...

Page 93: ...There 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 when the engine is not running WARNING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine ...

Page 94: ...eets 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 label The ECE mark consists of a circle sur rounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be dis pl...

Page 95: ...ersonal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of strong over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with knee pads and a j...

Page 96: ...parking 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 your right thumb and begin driving 7 Drive slowly at first Practice turning and using the throttle and brakes on level surfaces ...

Page 97: ...action 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 traction between the rear wheels allowing the turn to be made smoothly NOTE Practice making turns at slow speeds WARNING Turning at sharp angles or at excessive speeds can result in vehicle overturn and ...

Page 98: ...er 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 obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 99: ...se 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 excessively slippery surfaces Always reduce speed and use additional caution ...

Page 100: ...avel 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 skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward ...

Page 101: ...d when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual ...

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 prepared to take emergency action This may include quick dismounting of the vehicle 15 Maximum ...

Page 103: ...WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn resulting in severe injury or death Avoid crossing the side of a hill when possible Follow proper procedures as outlined in the owner s manual ...

Page 104: ...ation 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 the hill to maintain direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immedi ately ...

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 control or overturn and result in serious injury or death Avoid climbing steep hills 15 maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the own...

Page 106: ...brake 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 7 Restart the engine 8 Squeeze the rear brake lever 9 Release the parking brake and drive slowly controlling speed with the rear brake until the ATV is on more level ground 8 ft 2 4 m ...

Page 107: ...directly 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 loss of control and lead to serious injury or death Always operate slowly when traveling downhill ...

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 in the illus tration 4 Turn the fuel valve off ...

Page 109: ...h 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 After driving through water dry the brakes by applying light pressure to the levers while moving until braking action is normal If you do not perform this procedure your brakes may be ineffective Ma...

Page 110: ...e 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 result from driving this ATV in deeper water than recommended If your vehicle becomes immersed or is operated in water that exceeds the bottom of the footrests take it to your dealer for service before st...

Page 111: ...he 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 lands in the U S A is regulated by 43 CFR 8343 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This e...

Page 112: ...hat 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 installation of devices that effectively increase exhaust emissions beyond their legal lim its will void all manufacturer warranties and may violate laws governing the registration and operation of this veh...

Page 113: ...rtment 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 use must be inspected and serviced more frequently Record maintenance and service in the Maintenance Log beginning on page 190 ...

Page 114: ...arts 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 Severe Use Definition Frequent immersion in mud water or sand Racing or race style high RPM use Prolonged low speed heavy load operation Extended idle Short trip cold weather operation ...

Page 115: ...ion 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 item WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 116: ...e 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 Air filter pre filter main element Daily Inspect clean often replace as needed 152 Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric gre...

Page 117: ...st 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 in maintenance 82 XQ Brake lever travel brake freeplay 10 Monthly 100 160 Inspect regularly 141 145 E Spark plug 10 Monthly 100 160 Clean check condition adjust gap replace as needed 128 Idle speed 10...

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 Valve clearance 50 3 M 500 800 Check clearance see your dealer for adjustments Carburetor float bowl 50 6 M 500 800 Drain bowl periodically and prior to storage QE Throttle cable ETC switch 50 6 M 5...

Page 119: ...or 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 100 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years QE Fuel filter 100 12 M 1000 1600 Change filter 125 X Engine mounts 100 12 M 1000 ...

Page 120: ...pect 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 100 12 M 1000 1600 Inspect replace as needed Spark arrestor 300 36 M 3000 4800 Clean out 134 Q Toe adjustment Inspect periodically adjust when parts are replaced 146 ...

Page 121: ...ic 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 Suspension A Arm Polaris All Season Premium Grease or grease conforming to NLGI No 2 Inspect tighten fasteners grease also after washing ATV or driving in water ...

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

Page 123: ...o 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 Youth Oil or Synthetic SAE40 Outside air temperature is below 32 F 0 C Semi Synthetic 20W 40 CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommende...

Page 124: ...ean 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 moisture collecting in the crankcase If the oil level is over the full safe mark change the oil immediately 5 Add the recommended oil as needed 6 Reinstall the dipstick Dipstick Full Add Oil Safe Range ...

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 not allow hot oil to come into contact with skin ...

Page 126: ...etely 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 plug and crankcase should be clean and free of burrs nicks or scratches 9 Reassemble the pre filter screen and spring to the pre filter plug ...

Page 127: ...mended 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 engine and inspect for leaks 15 Check the oil level Add oil as needed to bring the level to the upper mark on the dip stick 16 Dispose of used oil properly ...

Page 128: ...r 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 attempt to clean the fuel filter ...

Page 129: ...change 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 Polaris prod ucts 1 Position the vehicle on a level surface 2 Remove the fill plug 3 View the oil level through the fill hole 4 If the level is low add the recommended oil 5 Reinstall the fill plug Fill ...

Page 130: ...earcase 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 fill plug hole threads 7 Reinstall the fill plug Check for leaks 8 Dispose of used oil properly Gearcase Capacity Outlaw 50 11 8 oz 350 ml ...

Page 131: ...ndition 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 can result in serious engine damage Always use Polaris rec ommended spark plugs WARNING A hot exhaust system and engine can cause serious burns Wear protective gloves when removing a spark plug for i...

Page 132: ...etor 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 not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Change 1 Remove the spark plug cap ...

Page 133: ...e 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 water is present 4 Remove the spark plug CAUTION If your vehicle becomes immersed major engine damage can result if the vehicle is not thoroughly inspected Take the vehicle to your dealer before starting...

Page 134: ...ce 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 soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the transmission follow the pro cedure on page 133 for drying the CVT Drain Screw ...

Page 135: ...bration 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 safety of this product How ever as the owner you have the following responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outl...

Page 136: ...tart 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 ...

Page 137: ...t 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 ficiently before proceeding Wear eye protection and gloves Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas ...

Page 138: ...synthetic 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 Replace the arrestor if damage is found 4 Reinstall the arrestor 5 Torque the bolts to 7 ft lbs 9 5 Nm Arrestor Screen Bolts ...

Page 139: ...ch 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 from your Polaris dealer are required for operation above 6 000 feet and temperatures below 40 degrees F 4 degrees C NOTE Continuous operation of the engine without proper jetting when required can cau...

Page 140: ...arbure 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 idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclock wise will lower RPM ...

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 adjusted removed only by consumers when they determine that their child is capable of han dling the additional speed Per ANSI SVIA 1 2001 sec 6 2 the unrestricted top speed is less than 15 MPH for the ...

Page 142: ...rottle 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 the jam nut after adjusting Jam Nut Screw ...

Page 143: ...tle 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 falls in to the acceptable limit Adjustment Nut 1 16 1 8 1 5 3 2 mm ...

Page 144: ...t 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 Specifications Model Front Brake Rear Brake Outlaw 50 08 12 2 3 mm 08 12 2 3 mm Measure Freeplay ...

Page 145: ...hicle 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 control 4 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn Front Brake Adjuster Nuts ...

Page 146: ...front 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 8 Verify that brake lever freeplay is at specification See page 141 9 Carefully lower the vehicle to the ground ...

Page 147: ...d 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 full turn 5 Verify that the left hand brake functions correctly 6 Verify that brake lever freeplay is at specification See page 141 7 Carefully lower the vehicle to the ground Rear Brake Wing Nut ...

Page 148: ...d 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 below Always service the brakes when there is no longer sufficient stopping ability at the specified lever travel setting Component Total Lever Travel Front brake lever 1 3 4 45 mm Rear brake lever 2...

Page 149: ...teering 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 the rear tires WARNING Severe injury or death can result from improper toe alignment and adjustment Do not attempt to adjust tie rod alignment All tie rod adjustments should be performed by an autho...

Page 150: ...s 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 16 1 8 2 3 mm more than the front measurement NOTE If you discover improper alignment see your Polaris dealer for service Stands Measure to rim ...

Page 151: ...ound 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 or decrease spring tension Rotate the adjuster either clockwise or counter clockwise to make adjust ments Adjuster ...

Page 152: ...r 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 a high pressure washer or gasoline to clean the drive chain CAUTION Adjusting or operating the ATV with improper rear drive chain slack can result in severe damage to the transmission and drive comp...

Page 153: ...he 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 procedure on page 151 1 4 1 2 6 12 mm Deflection ...

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 Hold the adjuster stud securely while tightening the jam nuts to avoid breaking the stud Housing Mount Bolts Chain Adjuster ...

Page 155: ...ips 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 foam filter lubricant to the foam filter Support Screen Cover Clips Foam Filter Gasket ...

Page 156: ...l 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 causing rapid wear and severe damage to the engine ...

Page 157: ...hicle 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 or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and possible serious personal injury or death Follow...

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 equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 mm or less ...

Page 159: ...s 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 frame 4 Remove the wheel bolts and remove the wheel 1 8 3 mm Wheel Bolts ...

Page 160: ...otation 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 be service by an authorized Polaris dealer Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your author...

Page 161: ...t 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 proper operation 4 Reinstall the lens cover Screws Cover Lamp ...

Page 162: ...light 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 sure the filament is horizontal 5 Reinstall the lamp retainer Press the retainer inward and turn it clockwise about 1 4 turn 6 Start the engine to make sure the lights come on If the lights do not oper...

Page 163: ...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 dielectric grease or petroleum jelly WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first ...

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 the top of the battery Remove the plate 5 Lift the battery out of the mounting bracket Mounting Bracket Bolts ...

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 mounting bracket and battery to the vehicle Tighten the three bolts 5 Verify that battery cables are properly routed Battery Storage Whenever the vehicle is not used for a period of three months or mor...

Page 166: ...e 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 repellents and chemicals will damage plastic surfaces Do not allow these types of products to contact the vehicle ...

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 washer to clean the vehicle Do not use medium to heavy duty compounds on the finish Always use clean cloths and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles...

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 damaged contact your Polaris dealer for free replacement Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any water that may have entered the engine ...

Page 169: ...ish 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 and pads for cleaning and polishing Old or reused cloths and pads may contain dirt particles that will scratch the finish ...

Page 170: ...the 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 month during storage and recharge as needed to maintain a full charge ...

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 the possibility of bacterial growth in the fuel system 3 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the fuel in the tank and carburetor 4 Stop the ...

Page 172: ...er 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 Maintenance Chart beginning on page 110 Transmission Oil Engine Oil Brake Fluid ...

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 4 Cover the vehicle with an appropriate cover NOTE Do not use plastic or coated materials They do not allow enough ventilation to prevent con densation and may promote corrosion and oxidation ...

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 offer enough support for tie down while transporting the unit Accessories Polaris has a wide range of accessories available for your ATV Please see your Polaris dealer ...

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 CVT Final Drive Chain Front Suspension Single control arm with 3 7 6 cm of travel Rear Suspension Spring over shock with 3 7 6 cm of travel ...

Page 176: ...e 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 210 lbs 95 3 kg Length Width Height 48 122 cm 31 5 80 cm 28 71 cm Wheel Base 33 84 cm Ground Clearance 4 10 cm Brake Light Standard Daytime Running Lights Standard ...

Page 177: ...uth 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 2873602 Premium AGL Synthetic Gearcase Lubricant qt 95 l 2872348 Chain Lube Aerosol ...

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 spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plugs Clogged fuel filter R...

Page 180: ...p 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 recommended fuel Incorrect ignition timing See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs ...

Page 181: ...lugs 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 ignition timing See your Polaris dealer Mechanical failure See your Polaris dealer Exhaust system leak See your Polaris dealer ...

Page 182: ...ge 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 Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electronic throttle control malfunction See your Polaris...

Page 183: ...uel 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 choke Inspect clean and or replace spark plugs Fuel is very high octane Replace with lower octane fuel Incorrect jetting See your Polaris dealer ...

Page 184: ...k 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 connections Check all connections and tighten Low battery voltage Recharge battery with 5 amp charger Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Electroni...

Page 185: ...olaris dealer REGISTRATION At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for warranty No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement If you have not signed ...

Page 186: ...rosion 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 are not compatible with the ATV The exclusive remedy for breach of this warranty shall be at Polaris exclusive option repair or replace ment of any defective materials or components or products THE ...

Page 187: ...S 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 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 controlling state law ...

Page 188: ...rform 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 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 are void because of state or federal law all other warranty terms will ...

Page 189: ...r 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 authorized Polaris dealer If you move or are traveling within the country where your vehicle was purchased Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells th...

Page 190: ...w 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 denied Notice If your vehicle is registered 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...

Page 191: ...irements 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 warranty covers components whose failure would increase an engine s emissions including electronic controls fuel injection exhaust gas recirculation aftertreatment or any other system utilized in thi...

Page 192: ...ON 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 limitation may not apply if it is inconsistent with the controlling state law This limited warranty excludes failures not caused by a defect in material or workmanship This limited warranty does not c...

Page 193: ...l 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 COMMENTS 10 Hours Break in 40 Hours 50 Hours 80 Hours ...

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: ...ying 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 104 Driving on Slippery Surfaces 96 97 Driving Over Obstacles 95 Driving Procedure 93 Driving Through Water 106 107 Driving Uphill 98 99 E Electronic Throttle Control 69 Emission Control Systems 108 10...

Page 198: ...Transmission 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 Safety Decals Age Warning 36 Clutch Cover Warning 39 No Passenger Warning 38 Operation Warning 35 Tire Pressure Warning 37 Safety Training 7 Seat Latch 21 Severe Use 111 Shock Spring Adjustment 148 Sig...

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 Oil 126 127 Transporting the ATV 171 Turning Around on a Hill 102 103 V Vehicle Identification Numbers 64 Vehicle Immersion 130 131 W Warranty 188 189 Washing the ATV 164 Wheel Hub Tightening 157 Wheel...

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Polaris 2008 Outlaw 50, Owner'S Manual

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