Polaris 2x4 2008 Owner'S Manual Download Page 69

Page: 69 / 124

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the

demand drive fluid at the inter-

vals outlined in the Periodic

Maintenance Chart beginning

on page 54. We recommend the

use of Polaris Premium

Demand Drive Hub Fluid. Use

of other oils may result in

improper operation of compo-

nents. See page 105 for the part

numbers of Polaris products.
Maintain the fluid level at the

bottom of the fill hole threads.

The fill plug is located on the

right side of the gearcase. The

drain plug is located on the bot-

tom right side of the gearcase.

Demand Drive Fluid Recommendations

Gearcase

Lubricant

Capacity

Fill Plug

Torque

Drain Plug

Torque

Demand Drive

Unit

Premium Demand Drive

Hub Fluid

5 oz.

(148 ml)

8-10 ft. lbs.

(11-13 Nm)

8-10 ft. lbs.

(11-13 Nm)

Drain Plug

Fill

Plug

Fill

Level

Summary of Contents for 2x4 2008

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Page 3: ...orcycles Always follow the instructions and recommendations in this manual The manual contains instructions for minor maintenance but informa tion about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technician Please see your dealer for all of your service needs during and after the warranty period For more inf...

Page 4: ... and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation 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 contained within whether whole or in part i...

Page 5: ...w Your Vehicle 5 Safety 6 Features and Controls 20 Operation 32 Emission Control Systems 53 Maintenance 54 Adjustments 101 Polaris Products 105 Troubleshooting 106 Specifications 110 Warranty 114 Maintenance Log 117 Index 120 ...

Page 6: ...4 ...

Page 7: ...our vehicle s identification numbers and key number in the spaces provided Remove the spare key and store it in a safe place An ignition key can be duplicated only by ordering a Polaris key blank using your key number and mating it with one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ___________________________________________________ Frame ...

Page 8: ...rt symbol 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 hazard 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 ...

Page 9: ...cations The warranty on your Polaris vehicle may be terminated if any equip ment has been added or if any modifications have been made that increase speed or power NOTE The addition of certain accessories including but not limited to mow ers blades tires sprayers and large racks may change vehicle han dling Use only Polaris approved accessories Know their function and effect on the vehicle WARNING...

Page 10: ...e at www polarisindustries com Never permit others to operate this vehicle unless they have read and under stand this manual and all product labels and have completed a certified safety training course 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 carrying passengers Never allow anyone under 16 year...

Page 11: ...s or face shield gloves boots long sleeves and long pants Never consume alcohol or drugs before or while operating this vehicle Never operate at excessive speeds Travel and turn at speeds appropriate for the ter rain visibility operating conditions and your experience Never attempt jumps or other stunts ...

Page 12: ...ating condition Follow the inspection and maintenance procedures outlined in this manual See page 35 Keep both hands on the handlebars Keep both feet on the footrests Always travel slowly when operating on unfamiliar terrain Use extra caution Use caution when operating on rough slippery or loose terrain ...

Page 13: ...llow the procedures outlined in this man ual for driving on hills See page 43 Never operate on hills too steep for this vehicle or for your abili ties Practice on smaller hills before attempting larger hills Avoid climbing hills steeper than 15 Always follow the procedures outlined in this man ual for driving downhill and for braking on hills See page 45 Always follow the procedures outlined in th...

Page 14: ...ys follow the procedures outlined in this manual for operating on slippery or loose surfaces Use extra caution Always avoid skidding or sliding See page 42 Always follow the procedures outlined in this manual for driving through water Never drive through deep or fast flowing water See page 48 Always follow the procedures outlined in this manual for driving in reverse See page 51 Always use the siz...

Page 15: ...ys avoid operating this vehicle on paved surfaces including sidewalks driveways parking lots and streets Never operate this vehicle on a public street road or highway including a dirt or gravel road Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental start ing Hot components can cause serious burns and fire Do not touch hot exhaust system compone...

Page 16: ...oper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate without proper training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steerin...

Page 17: ...5 Tire Pressure Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH TIRE PRESSURE IN PSI KPa FRONT 5 34 5 REAR 5 34 5 MAXIMUM WEIGHT CAPACITY 365 lbs 166 kg INCLUDES WEIGHT OF OPERA TOR CARGO AND ACCESSORIES Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecure...

Page 18: ...loss of control resulting in SEVERE INJURY or DEATH 7172566 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7172559 No Passenger Warning Clutch Cover Warning Age 16 Warning Rack Warning Rack Warning ...

Page 19: ...Max Rack Loads Front 70 lbs 32 kg Rear 100 lbs 46 kg Reverse Override Warning 4X4 Models WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied Loss of control or forward flipover may result especially in AWD See Owner s Manual Override Switch 2X4 Models Reverse speed is limited Reverse override is controlled by the override switch ...

Page 20: ... 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 surrounding the letter E followed by the distinguishing number of the country which has granted approval The approval number and serial number will also be displayed on the label Helmet Eye Protection Gloves Boots Long Pants Long Sleeves E4 05103...

Page 21: ...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 sturdy over the calf boots with low heels Clothing Always wear long sleeves and long pants to protect arms and legs Riding pants with kneepads and a je...

Page 22: ...heel Drive in reverse if the AWD switch is on This switch is also used to toggle through the modes of the rider information center See page 30 WARNING Activating the override switch while the throttle is open can cause loss of con trol resulting in severe injury or death Do not activate the override switch while the throttle is open Mode Reverse Override Switch Main Key Switch Engine Stop Switch H...

Page 23: ...ight switch to turn the lights on and off and to change the lights from high beam to low beam NOTE The lights won t work unless the key is in the ON position and the engine stop switch is in the RUN position All Wheel Drive Switch 4x4 Models See page 29 for all wheel drive information WARNING Operating this vehicle on streets or roads especially in darkness could result in an accident and serious ...

Page 24: ... throttle controls could cause an accident and lead to severe injury or death Never start or operate this vehicle 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 fre...

Page 25: ... and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs WARNING Operating this vehicle with a spongy brake lever can result in loss of braking which could cause an accident Never operate thi...

Page 26: ...tant Safeguards The parking brake may relax if left on for a long period of time Always block the wheels to prevent rolling Always block the wheels on the downhill side of this vehicle if leav ing it parked on a hill Another option is to park in a sidehill position Never depend on the parking brake alone if this vehicle is parked on a hill Always block the wheels to prevent rolling WARNING Operati...

Page 27: ... the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently for the auxiliary brake system See page 71 WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxilia...

Page 28: ...ne number of 87 R M 2 octane Do not use E 85 fuel Fuel Valve The fuel valve is located on the bottom of the fuel tank Access the fuel valve through the right front wheel well or from the front of the vehicle ON For normal operation OFF For vehicle storage and when transporting Refuel when the instrument gauge indicates a low fuel level Fuel Filter The in line fuel filter should be replaced by your...

Page 29: ... Neutral R Reverse Whenever this vehicle is left unattended always place the transmission in gear and lock the parking brake CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Gear Selector ...

Page 30: ...ust until the engine rolls past the stroke then stop pulling immediately 3 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start the engine 4 Repeat all steps until the engine starts 5 Make sure the handle is fully seated on the housing CAUTION Extending the recoil starter rope until it stops can cause damage to the recoil assembly Do not exte...

Page 31: ...here is no limit to the length of time the vehicle may remain in AWD Engaging AWD The AWD switch may be turned on or off while the vehicle is moving Initially the vehicle s electronic system will not enable the AWD until the engine RPM is below 3100 Once enabled the AWD remains enabled until the AWD switch is turned off If the switch is turned off while the demand drive unit is moving it will not ...

Page 32: ...hange modes press and release the mode button see page 31 as often as needed to reach the odometer mode 2 In the odometer mode press and hold the mode button until the let ters flash then release the button 3 Press and release the button one more time When the display stops flashing the mode has been set CAUTION High water pressure may damage vehicle components Wash this vehicle by hand or with a ...

Page 33: ...E If using the mode button to program the rider information center or to toggle through the options the transmission cannot be in reverse Odometer The odometer records the distance traveled by the vehicle Trip Meter The trip meter records the distance traveled by the vehicle on each trip if it s reset before each trip To reset the trip meter toggle to the trip meter mode Press and hold the mode bu...

Page 34: ... 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 short time Turn the fuel valve off whenever the vehicle is stored or parked WARNING The engine exhaus...

Page 35: ...ficient performance and longer life for these components Install the accessory oil cooler when the following conditions exist The vehicle will be used for towing heavy loads The vehicle will be used for dragging ground surfaces or performing similar activities The vehicle is normally operated when the air temperature is above 100 F 38 C CAUTION Excessive heat build up during the first three hours ...

Page 36: ... 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 35 6 Pull only light loads 7 During the break in period change both the oil and the filter at 20 hours PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutche...

Page 37: ...pressure 75 Wheels fasteners Inspect ensure fastener tightness 75 77 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 26 61 Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 22 104 Indicator lights switches Ensure operation 20 Engine stop switch Ensure proper operation 21 Air filter pr...

Page 38: ... pull the choke knob out until it stops NOTE The variable choke is fully on when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during opera tion as excess fuel wash ing into the engine oil will increase wear on engine components 7 Move the engin...

Page 39: ...ine does not start and all conditions are favorable change the spark plug and try again 10 If the engine slows or stops position the choke knob half way in to allow proper engine warm up Vary the engine RPM slightly with the throttle to aid in warm up When the engine idles smoothly push the choke completely in Cold Weather Operation If this vehicle is used year round check the oil level frequently...

Page 40: ...to maintain stable driving conditions Do not obstruct the headlight beam with cargo Towing Loads Always attach a towed load to the hitch point If towing a load reduce rear rack cargo weight by the amount of tongue weight The combina tion of rear rack cargo weight and tongue weight must not exceed the rear rack capacity CAUTION Using an improper hitch or exceeding the maximum tongue weight capacity...

Page 41: ...le operating conditions which could result in loss of control of the vehi cle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying...

Page 42: ...ands on the handlebars 3 Start the engine and allow it to warm up 4 Shift the transmission into gear 5 Check your surroundings and determine your path of travel 6 Release the parking brake 7 Slowly depress the throttle with your right thumb and begin driving 8 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 43: ...on of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This tech nique alters the balance of trac tion between the rear wheels allowing the turn to be made smoothly The same leaning technique should be used for turning in reverse NOTE Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning at sharp...

Page 44: ...urning the handlebars in the direction of the skid and shifting your body weight forward CAUTION Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Always allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin to lose traction WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire...

Page 45: ...e opening 6 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle WARNING Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in seri ous injury or death Avoid climbing steep hills 25 maximum Use extreme caution when operating on hills and follow proper oper...

Page 46: ... your feet on the footrests 4 Steer slightly into the hill to maintain vehicle direction NOTE If the vehicle begins to tip quickly turn the front wheel downhill if pos sible or dismount on the uphill side immediately 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 poss...

Page 47: ...fore operating your vehicle learn how to use the auxiliary brake for emergency situations if single lever brakes become inoperable WARNING Excessive speed when traveling downhill can cause loss of control and seri ous injury or death Slow down Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control and serious injury or death Apply the brakes graduall...

Page 48: ...46 OPERATION Driving Safely Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hill Use the K turn to turn around 8 ft 2 4 m ...

Page 49: ...ill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s point ing across the hill or slightly downward 6 Lock the parking brake Remount the vehicle from the uphill side keeping body weight uphill 7 Start the engine with the transmission still in forward 8 Release the parking...

Page 50: ...of the footrests Follow these procedures when operating through water 1 Determine water depths and current before crossing 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal Maximum Depth ...

Page 51: ...efully 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 If your vehicle becomes immersed and it s impossible to take it to a dealer before starting it follow the steps described on page 84 Have the vehicle serviced by your dealer at the first opportunity CAUTION Major engine damage can result if the vehic...

Page 52: ...the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hid den obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 53: ...ly increased Do not operate at wide open throttle WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines a...

Page 54: ...ncline Avoid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in gear 3 Lock the parking brake 4 Always block the rear wheels on the downhill side 5 Turn the fuel valve off ...

Page 55: ... engine design including factory set fuel delivery and ignition The engine and related components must be maintained at Polaris specifications to achieve optimal performance Engine idle speed is the only adjustment Polaris recommends that the operator perform Any other adjustments should be performed by an authorized Polaris dealer Electromagnetic Interference This spark ignition system complies w...

Page 56: ...ice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour 16 km h Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition Frequent immersion in mud water or sand Racing or race style ...

Page 57: ...ed service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions Q Have an authorized Polaris dealer perform these services WARNING Improperly performing the procedures marked with a Q could result in com ponent failure and lead to serious injury or death Have an authorized Polaris dealer perform these services ...

Page 58: ...ls fasteners Pre Ride Frame fasteners Pre Ride X Engine oil level Pre Ride X E Air filter pre filter Daily Inspect clean often replace as needed X Air box sediment tube Daily Drain deposits when visible Headlamp tail lamp Daily Check operation apply dielectric grease if replacing X E Air filter main element Weekly Inspect replace as needed Recoil housing if applicable Weekly Drain water as needed ...

Page 59: ...pect adjust replace as needed X Engine oil change 100 H 6 M 1000 1600 Perform a break in oil change at 20 hours X Oil filter change 100 H 6 M 1000 1600 Replace with oil change X Oil tank vent hose if equipped 100 H 6 M 1000 1600 Inspect routing condition Q E Valve clearance 100 H 12 M 1000 1600 Inspect adjust Q E Fuel system filter 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve ...

Page 60: ...chever comes first Remarks Hours Calendar Miles Km Q Clutches drive and driven 100 H 12 M 1000 1600 Inspect clean replace worn parts Q Front wheel bearings 100 H 12 M 1000 1600 Inspect replace as needed Q Brake fluid 200 H 24 M 2000 3200 Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out Idle speed Adjust as needed Q Toe adjustment Inspect periodically adjust when parts are repla...

Page 61: ...Brake Fluid DOT 4 Only See page 70 Transmission Oil Polaris AGL Synthetic Gearcase Lube See page 64 Front Demand Drive Unit Front Gearcase Premium Demand Drive Hub Fluid See page 67 Front Prop Shaft Yoke Polaris Premium U Joint Lube Grease fittings 3 pumps maxi mum every 500 miles 800 km before long periods of storage or after pressure washing or submerging Control Arm front and rear Bearing Carri...

Page 62: ...ed to be changed more frequently if Polaris oil is not used Always use 2W 50 oil Follow the manufacturer s recommendations for ambient tempera ture operation Oil Specifications CAUTION Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Lubricant Capacity Drain Plug Torque PS 4 PLUS Performance Synthetic 2W ...

Page 63: ...ission in neutral 3 Lock the parking brake 4 Start the engine Allow it to idle for 30 seconds Stop the engine 5 Remove the dipstick Wipe it dry with a clean cloth 6 Reinstall the dipstick completely 7 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 8 Reinstall the dipstick Dipstick Safe Add Oil Safe Range ...

Page 64: ... 4 Start the engine Allow it to idle for two to three minutes Stop the engine 5 Clean the area around the drain plug 6 Place a drain pan under the vehicle 7 Remove the drain plug Use a 6 mm Allen wrench 8 Drain the oil 9 Reinstall the drain plug with a new sealing washer NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 10 Torque to spec...

Page 65: ...ll the new oil filter After the filter contacts the engine surface turn it 1 2 turn by hand 15 Remove the dipstick 16 Add the recommended oil See page 60 17 Reinstall the dipstick 18 Start the engine Allow it to idle for two minutes 19 Stop the engine 20 Check for oil leaks 21 Remove the dipstick and check the oil level Add oil as needed Maintain the oil level in the safe range Do not overfill 22 ...

Page 66: ... The fill plug is located on the left side of the vehicle under the rear fender behind the wheel The drain plug is located behind the wheel well Transmission Oil Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Transmission 2x4 Premium AGL Synthetic Gearcase Lubricant 15 2 oz 450 ml 15 ft lbs 20 Nm 15 ft lbs 20 Nm Transmission 4x4 Premium AGL Synthetic Gearcase Lubric...

Page 67: ...cle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use a 15 mm wrench 5 Check the oil level 6 Add oil as needed Do not overfill 7 Reinstall the fill plug Torque to specification See page 64 for recom mendations ...

Page 68: ... wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use a 15 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 64 for recommendations 9 Add the recommended oil 10 Reinstall the fill plug Torque to specification See page 64 for recommenda tions 11 Check for leaks 12 Dispose of used oil properly ...

Page 69: ... of compo nents See page 105 for the part numbers of Polaris products Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the gearcase The drain plug is located on the bot tom right side of the gearcase Demand Drive Fluid Recommendations Gearcase Lubricant Capacity Fill Plug Torque Drain Plug Torque Demand Drive Unit Premium Demand Drive Hu...

Page 70: ...el surface 2 Place the transmission in gear 3 Lock the parking brake 4 Remove the fill plug Use an 8 mm Allen wrench 5 Check the oil level 6 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads 7 Reinstall the fill plug Torque to specification See page 67 ...

Page 71: ...emove the fill plug Use an 8 mm Allen wrench 5 Place a drain pan under the gearcase 6 Remove the drain plug Use an 11 mm wrench 7 Allow the oil to drain completely 8 Clean and reinstall the drain plug Torque to specification See page 67 9 Add the recommended fluid 10 Reinstall the fill plug Torque to specification 11 Check for leaks 12 Dispose of used oil properly ...

Page 72: ...nsure proper diaphragm operation always fill the reservoir as needed whenever the cover is loosened or removed Do not overfill WARNING An over full master cylinder may cause brake drag or brake lock up which could result in serious injury or death Maintain brake fluid at the recom mended level Do not overfill WARNING Never store or use a partial bottle of brake fluid Brake fluid is hygroscopic mea...

Page 73: ...ght 2 View the fluid level through the indicator win dow eye on the top of the master cylinder NOTE The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 3 Add the recommended fluid as needed Do not overfill Foot Brake The brake fluid reservoir is located on the right side of the vehicle Maintain the fluid level between the minimum and maximum marks Do not o...

Page 74: ...ommended to keep the brake system in good operating condition Check more often if brakes are used heavily under normal operation 1 Always keep brake fluid at an adequate level See page 70 2 Check the brake system for fluid leaks 3 Check the brakes for excessive travel or spongy feel 4 Check the friction pads for wear damage and looseness Replace the pads when the fric tion material is worn to 03 8...

Page 75: ... NOTE If available you may use a long straight edge instead of string 4 Measure the distance from the string to the rim at the front 1 and rear 2 of the front rim The rear measurement should be 2 3 mm more than the front mea surement on each side of the vehicle to obtain the recommended 3 6 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle NOTE If you discove...

Page 76: ...ris dealer for service before operating the vehicle Side Panel Removal 1 Remove the seat 2 Grasp the top of the side panel and pull it outward to remove it Footwell Removal 1 Remove the two screws on the bottom of the footwell 2 Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders 3 Remove the footwell Screws Rivets Rivets ...

Page 77: ...e performed by your authorized Polaris dealer WARNING Operating your vehicle with worn tires improperly inflated tires non standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Maintain proper tire pressure as described on the decal on your vehicle and in the owner s manual Always use original equipment size and t...

Page 78: ...ehicle on a level surface 2 Place the transmission in gear 3 Lock the parking brake 4 Loosen the wheel nuts slightly 5 Place a suitable stand under the footrest frame to raise the wheel slightly off the ground 6 Remove the wheel nuts 7 Remove the wheel ...

Page 79: ...rque Specifications Check the wheel nut torques occasionally and when they ve been loos ened for service WARNING Improperly installed wheels can adversely affect tire wear and vehicle han dling which can result in serious injury or death Always ensure that all nuts are torqued to specification Do not service axle nuts that have a cotter pin installed See your Polaris dealer Nut Type Nut Torque Lug...

Page 80: ... water then rinse and let dry 9 Remove the breather filter 10 Wash the breather filter in soapy water then rinse and let dry 11 Reinstall the breather filter 12 Reinstall the sleeve over the air filter Replace the filter if needed 13 Reinstall the air filter into the air box 14 Reinstall the air box cover and the seat CAUTION Operation of your vehicle without a breather filter can cause engine dam...

Page 81: ... Lock the parking brake 4 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height NOTE Include rider weight on the seat when measuring 5 Start the engine Turn the headlight switch to high beam 6 Observe the headlight aim on the wall The most intense part of the headlight beam should be two inches 5 cm below the mark on the wall 7 Loosen the...

Page 82: ...ly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 From the rear of the brake light remove the two screws holding the lens cover in place Remove the lens cover 2 Remove the lamp and replace it with a new lamp 3 Test the light for proper operation 4 Reinstall the lens cover WARNING Poor lighting while driving can result in severe injury or deat...

Page 83: ...ng is completely dry before reinstalling the drain plug 1 Place the transmission in gear 2 Lock the parking brake 3 Stop the engine 4 Remove the drain screw on the bottom of the recoil housing 5 Reinstall the drain screw NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if the crank case drain is opened ...

Page 84: ...the spark plug for correct color See page 83 1 Remove the left side panel 2 Rotate the spark plug cap 1 4 turn and pull it off the spark plug 3 Using the special wrench provided in the tool pouch rotate the spark plug counterclockwise to remove it CAUTION Using non recommended spark plugs can result in serious engine damage Always use Polaris recommended spark plugs Plug Condition Torque Specifica...

Page 85: ...trodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service NOTE The tip should not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments Wet Fouled Spark Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer ...

Page 86: ...s using the electric start 7 Dry the spark plug Reinstall the plug or install 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 proce dure 11 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not 12 If water has been ingested into the PVT follow the procedure on ...

Page 87: ... cm higher than the front Block the wheels 10 Place the transmission in neutral Lock the parking brake Repeat steps 6 to 8 until no more particles are expelled 11 Stop the engine Allow the arrestor to cool 12 Reinstall the arrestor plug and remove the exhaust outlet cover or plug WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or dea...

Page 88: ...tional loads on components The PVT 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 However as the owner you have the fol lowing responsibilities to make sure this system remains safe Always follow all recommended maintenance procedures See your dealer as outlined in the owne...

Page 89: ...low the water to drain com pletely Reinstall the drain plug 4 Start the engine Place the trans mission in neutral 5 Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches NOTE Do not hold the throttle wide open for more than 10 seconds 6 Allow the engine RPM to settle to idle speed then shift the trans mission into forward gear 7 Test for belt slippage If ...

Page 90: ...ith clean shop towels Coat the termi nals with dielectric grease or petroleum jelly Be careful not to allow cleaning solution or tap water into a conventional battery WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk ...

Page 91: ...attery out of the vehicle Be careful not to tip a conventional battery sideways which could spill electrolyte WARNING Improperly connecting or disconnecting battery cables can result in an explo sion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last CAUTION If elect...

Page 92: ...tions and securely installed Route the tube away from the frame and vehicle body to prevent con tact with electrolyte 4 On conventional batteries coat the terminals with dielectric grease or petroleum jelly 5 Connect and tighten the red positive cable first 6 Connect and tighten the black negative cable last 7 Secure the battery hold down strap 8 Verify that cables are properly routed NOTE Cables ...

Page 93: ...Tender charger or by charging about once a month to make up for normal self discharge Battery Tender can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point See page 105 for the part numbers of Polaris products Battery Fluid Conventional Battery A poorly maintained battery will deteriorate rapidly Check the battery...

Page 94: ...the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh charge follow all instructions carefully 1 Check the battery voltage with a voltmeter or multimeter A...

Page 95: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 96: ...th 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 that will scratch the finish CAUTION High water pressure may damage co...

Page 97: ...ealer 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 or exhaust system Polishing the Vehicle Polaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle Follow the instructions on the container Polishing Tips Avoid the use...

Page 98: ...nt Never use abrasive cleaners on plated or painted surfaces 2 Rinse well with clear water Soap detergents salt dirt mud and other elements can cause corrosion 3 Polish the clean chrome wheels periodically Use an automotive grade chrome polish 4 Routinely and liberally apply a weather resistant wax to each pol ished chrome wheel Choose a product suitable for chrome finishes Read and follow the pro...

Page 99: ... exhaust sys tems 3 Allow the engine to run for 15 20 minutes to allow the stabilizer to disperse through the fuel in the tank and carburetor 4 Turn the fuel valve off 5 Drain the carburetor bowl Oil and Filter Change the oil and filter See page 62 Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter 2 Clean the air box 3 Clean or replace the breather filter 4 Drain the...

Page 100: ...e machine so the engine is level or tilted slightly rearward 3 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 4 Reinstall the spark plug Torque to specification 5 Apply dielectric grease to the inside of the spark plug cap Reinstall the cap 6 Turn the engine over several times using the recoil starter Oil will be forced in and around the pi...

Page 101: ...f the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine Polaris cover NOTE Do not use plastic or coated materials They do not allow enough ven tilation to prevent condensation and may promote corrosion and oxi dation Accessories Auxiliary power outlets provide 12 volt power for operating accesso ries Accessory outlets are available for all models Polaris also has ...

Page 102: ...he transmission in gear 3 Lock the parking brake 4 Turn the fuel valve off 5 Secure the fuel cap oil cap and seat 6 Remove the key to prevent loss during transporting 7 Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets ...

Page 103: ...stments The front and rear shock absorber springs are adjustable Rotate the adjuster either clockwise or counterclockwise to increase or decrease spring tension Always adjust both sides equally NOTE Accessory springs are available through your Polaris dealer Rear Adjuster Front Adjuster ...

Page 104: ... right 3 Torque the front two bolts to 10 12 ft lbs 14 17 Nm then torque the rear two bolts A gap of up to 1 8 3 mm will remain at the rear bolts 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 the adj...

Page 105: ...om 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 cause poor performance overheating or PVT or engine damage See your Polaris dealer for more information about jetting for conditions in your area Carburetor Engine Idle RPM Adjustment If the engine idle s...

Page 106: ...expose the end of the inline cable adjuster 3 Loosen the adjuster lock nut 4 Rotate the boot to turn the adjuster until 1 16 to 1 8 1 5 3 mm of freeplay is achieved at the thumb lever NOTE While adjusting freeplay be sure to flip the throttle lever back and forth 5 Tighten the lock nut 6 Squeeze the end of the rub ber boot and slide it over the cable adjuster to its original position Lock Nut Adju...

Page 107: ... 2872277 Premium Demand Drive Hub Fluid 2 5 gal Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2 oz 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871329 Dielectric Grease NyogelTM 2872073 Chain Lube Aerosol 6 25 oz 287...

Page 108: ...nge only if equipped Utility use plowing Use low range only if equipped Stuck in mud or snow Shift the transmission to low range if equipped Care fully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system D...

Page 109: ...el valve on Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Overuse of choke Inspect clean and or replace spark plugs Water or fuel in crankcase Immediately see your Polaris dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failu...

Page 110: ...d tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer...

Page 111: ...ecs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Possible Cause Solut...

Page 112: ...g Overall Length 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carburetor Mikuni BST ...

Page 113: ...AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Tripmeter Hourmeter Standard Fuel Gauge Standard Tool Kit Standard ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 air box plugs Above 2700 Above 9000 Same main jet R...

Page 114: ...1213 lbs 550 kg Overall Length 74 in 188 cm Overall Width 42 in 107 cm Overall Height 45 5 in 116 cm Wheelbase 46 in 117 cm Ground Clearance 8 in 20 cm Minimum Turning Radius 62 5 in 159 cm unloaded Engine Model Number Type ES300PFE010 4 Cycle Single Cylinder Lubrication Wet sump Engine Cooling Air Displacement 299 cc Bore x Stroke 78 5 x 68 Alternator Output 250 w Compression Ratio 9 2 1 Carburet...

Page 115: ...ghts 12V 8 26W Brake Light 12V 26 9W Battery 12V 14AH DC Plug In rear Accessory Windshield Accessory Speedometer Odometer Tripmeter Hourmeter Standard Fuel Gauge Standard Tool Kit Standard ALTITUDE Meters Feet AMBIENT TEMPERATURE Below 40 F Below 5 C 40 F and above 5 C and above 0 900 0 3000 145 140 900 1800 3000 6000 Same main jet Remove 2 air box plugs 1800 2700 6000 9000 Same main jet Remove 4 ...

Page 116: ...laris within ten days Upon receipt of this registration Polaris will record the registration for warranty THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE 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 no...

Page 117: ...ible with the Quadricycle The exclusive remedy for breach of this war ranty shall be at Polaris exclusive option repair or replacement of any defective materi als or components or products THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ...

Page 118: ...PONSIBILITY Polaris suggests that you use your original selling dealer however you may use any Polaris Servicing Dealer to perform 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 whi...

Page 119: ... section of your manual to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 120: ...118 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 121: ...119 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 122: ...hing Chart 2X4 111 Clutching Chart 4X4 113 Cold Weather Operation 37 Corrosion Removal Chrome 96 D Demand Drive Fluid 67 69 Drive Belt Wear Burn 106 Drivetrain Break In 34 Driving Downhill 45 Driving in Reverse 51 Driving on a Sidehill 44 Driving on Slippery Surfaces 42 Driving Over Obstacles 50 Driving Procedures 40 Driving Safely 40 52 Driving Through Water 48 49 Driving Uphill 43 E Electromagne...

Page 123: ...rride Switch 20 P Parking Brake 24 Parking on an Incline 52 Periodic Maintenance Chart 54 58 Polaris Product List 105 Polishing the Vehicle 95 Pre Ride Checklist 35 PVT Break In 34 PVT Drying 87 PVT System 86 87 R Recoil Housing 81 Recoil Starter 28 Reverse Operation 51 Reverse Override Switch 20 Rider Information Center 31 Riding Gear 18 19 S Safety Decals 14 17 No Passenger Warning 16 Age 16 War...

Page 124: ...ightening 75 Tread Depth 75 Wheel Installation 77 Wheel Nut Torque 77 Wheel Removal 76 Toe Alignment 73 Towing Loads 38 Training Safety 7 Transmission Oil 64 66 Transporting the Vehicle 100 Turning Around on a Hill 46 47 Turning the Vehicle 41 V Vehicle Identification Numbers 5 Vehicle Immersion 84 W Warning Symbols 6 Washing the Vehicle 94 95 Wheel Hub Tightening 75 Wheel Installation 77 Wheel Nu...

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Polaris 2x4 2008, Owner'S Manual

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