Polaris 500 HHO 2013 Owner'S Manual Download Page 121 | Manualshive

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117

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 67.
• Demand drive unit (front gearcase)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Support the front end of the machine so the engine is level or tilted

slightly rearward.

2. Remove the spark plug. Rotate the piston to BDC and pour two

ounces (59 ml) of engine oil into the cylinder.

3. Reinstall the spark plug. Torque to specification.

4. Apply dielectric grease to the inside of the spark plug cap. Reinstall

the cap.

5. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protec-
tive film of fresh oil.

6. If POLARIS fuel system additive is not used, the fuel tank, fuel

lines, and carburetor should be completely drained of gasoline.

7. To eliminate any fuel remaining in the carburetor, run the engine

until it stops.

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Summary of Contents for 500 HHO 2013

Page 1: ...manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Manual for Maintenance and Safety Sportsman Tour...

Page 2: ...r s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to...

Page 3: ...The text is printed on 100 recycled with 40 post consumer waste PCW...

Page 4: ...H DRUGS OR ALCOHOL without proper ATV 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 unless pa...

Page 5: ...l utility and recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle For safe and enjoyable operat...

Page 6: ...een 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 omission...

Page 7: ...TENTS Introduction 4 Safety 7 Features and Controls 26 Operation 42 Emission Control Systems 66 Maintenance 67 Troubleshooting 120 Specifications 124 POLARIS Products 126 Warranty 127 Maintenance Log...

Page 8: ...ituation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indi...

Page 9: ...ration is prohibited for anyone under 16 years of age Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training...

Page 10: ...r 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 VIN _...

Page 11: ...derCoursesm for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcemen...

Page 12: ...ds estab lished 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 m...

Page 13: ...protect arms and legs Rid ing pants with kneepads and a jersey with shoulder pads provide the best protection Equipment Modifications We strongly recommend that consumers do not install on a POLARIS A...

Page 14: ...nt types of terrain Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle See page 7 Never permit a guest to operate the ATV unless the gu...

Page 15: ...e off whenever the vehicle is stored or parked Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time Never start the engine or let it run...

Page 16: ...carry a passenger until you have at least two hours of driving experience with this vehicle Carrying More Than One Passenger Carrying more than one passenger greatly reduces the operator s ability to...

Page 17: ...den turns or stops Operating on Public Roads Operating this ATV on public streets roads or highways could result in a collision with another vehicle Never operate the ATV on any public street road or...

Page 18: ...should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Turning Impr...

Page 19: ...dures for traveling down hills as described in the owner s manual See page 58 Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avo...

Page 20: ...ure described in the owner s manual See page 56 If the ATV begins rolling backwards Keep operator and passenger body weight uphill Never apply engine power Never apply the rear brake while rolling bac...

Page 21: ...n Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control...

Page 22: ...stacles could cause loss of control or overturn Before operating in a new area check for obstacles Avoid operating over large obstacles such as rocks and fallen trees If unavoidable use extreme cautio...

Page 23: ...lightly several times while driving The friction will help dry out the pads Improper Cargo Loading Overloading the ATV or carrying towing cargo improperly may cause changes in handling which could cau...

Page 24: ...urrents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route ATV operators assume all risk associated wit...

Page 25: ...increased risk of overturn and loss of control Never secure a passenger to the vehicle or to the operator with a belt rope or similar device Hot Exhaust Systems Exhaust system components are very hot...

Page 26: ...isk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand ho...

Page 27: ...is securely in place THE OPERATOR MUST ALWAYS use proper riding techniques to avoid overturns on hills and rough terrain and in turns avoid paved surfaces pavement may seriously affect handling and c...

Page 28: ...n result in severe injury or death Cold tire pressure Front 5 0 psi 34 5 kPa Rear 5 0 psi 34 5 kPa Maximum weight capacity 485 lbs 220 kg 7175642 Hitch Capacity Label TRAILER MAX WEIGHT 1225 LBS 557 K...

Page 29: ...ehicle with guard removed 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 NO STEP 7172563 Reverse...

Page 30: ...ING Activating the override switch while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before activating the override switch Th...

Page 31: ...p switch will shut off all electrical power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 47 AWD Switch Use the AWD switch to engage 4X4 or 2X4 S...

Page 32: ...tle release switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle release switch or replace it with any after market throttle me...

Page 33: ...the brake lever toward the handlebar to apply the front and rear brakes These brakes are hydraulically activated disc type brakes that are activated by only one lever Always test brake lever travel a...

Page 34: ...lead to early brake fade and the possibility of brake failure which could result in an accident After opening a bottle of brake fluid always discard any unused portion Check the brake fluid in the mas...

Page 35: ...unlocked position WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire Always check to be sure the parking brake is disengaged before operating The parking...

Page 36: ...s a backup for the main brake system Should the main system fail use the auxiliary foot brake Since this is a rear brake only it will not be as effective as the all wheel single lever system The auxil...

Page 37: ...age Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven...

Page 38: ...ear rack Press down firmly on the seat pad until the latch clicks Fuel Filter The in line fuel filter should be replaced by your dealer after every 100 hours of operation or annually Do not attempt to...

Page 39: ...t will automatically disengage There 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 vehic...

Page 40: ...nction that limits the ATV s speed to approximately 7 9 MPH 11 14 km h Refer to page 26 for additional information NOTICE High water pressure may damage ATV components Wash the ATV by hand or with a g...

Page 41: ...ndicator 4 Service Interval Diagnostic Mode Indicator 5 Low Battery and Over Voltage This warning usually indicates that the ATV is operating at an RPM too low to keep the battery charged It may also...

Page 42: ...es traveled by the ATV on each trip if it s reset before each trip To reset the trip meter select the trip meter mode Press and hold the mode button override button until the total changes to 0 In the...

Page 43: ...nd on Any move ment of the tires will also cause the gauge to exit the diagnostic mode To enter the diagnostics mode 1 Turn the key switch off and wait 10 seconds 2 Lock the parking brake 3 Place the...

Page 44: ...your dealer for all major repairs Gear Circuit Diagnostic Screen This screen displays the resistance value in ohms being read at the gear switch input of the gauge This screen is for informational pur...

Page 45: ...button 4 Press and release the mode button once to advance the setting by one hour Press and hold the mode button to advance the hours quickly 5 If you scroll past the intended number press and hold...

Page 46: ...POLARIS ATV is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components wi...

Page 47: ...ecks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 44 6 Pull only light loads 7 Change both the oil and the filter at 25 hours 8 Check fluid levels of...

Page 48: ...ation Tires Inspect condition and pressure 87 Wheels fasteners Inspect ensure fastener tightness 87 88 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 34 72 Coola...

Page 49: ...a manner appropriate for your skills your passenger s skills and operating conditions Never operate at excessive speeds Never attempt wheelies jumps or other stunts Never remove your hands from the h...

Page 50: ...icle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and alwa...

Page 51: ...ome wet fouled 7 If the engine is cold pull the choke knob out until it stops Tip The variable choke is fully on when the knob is pulled com pletely out The choke is off when the knob is pushed comple...

Page 52: ...over choked when warm depress the throttle lever fully while cranking to aid in starting Release the throttle lever immediately after the engine starts If the engine does not start and all conditions...

Page 53: ...side 6 Sit upright with both feet on the footrests and both hands on the handlebars 7 Start the engine and allow it to warm up 8 Shift the transmission into gear 9 Check your surroundings and determin...

Page 54: ...age 8 4 Perform the pre ride inspec tion See page 44 5 Always make sure the pas senger seat is installed and securely latched before operating with a passenger 6 Lock the parking brake 7 Mount the veh...

Page 55: ...and both hands on the passenger grab handles at all times The passenger should never hold on to the operator Never secure a passenger to the vehicle or to the operator with a belt rope or similar devi...

Page 56: ...teer in the direction of the turn 4 Keep both feet on the foot rests 5 Lean your upper body to the inside of the turn while sup porting your weight on the outer footrest This technique alters the bala...

Page 57: ...traction NOTICE Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging AWD or engage AWD before wheels begin...

Page 58: ...lls with excessively slippery or loose surfaces 5 Keep both feet on the footrests 6 Shift body weight uphill A passenger should also shift body weight uphill 7 Proceed at a steady rate of speed and th...

Page 59: ...ow these precautions 1 Slow down 2 Avoid crossing the side of a steep hill 3 Do not cross a hillside with a passenger on board Ask the passenger to dismount and walk across the hillside before remount...

Page 60: ...56 OPERATION 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 61: ...urns to firm level ground 4 Staying uphill 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 yo...

Page 62: ...hill with the transmission in neutral 4 Slow down Never travel down a hill at high speed 5 Drive straight downhill Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply...

Page 63: ...id and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to y...

Page 64: ...onstantly alert for haz ards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible 4 Never at...

Page 65: ...turning at sharp angles 6 Never open the throttle suddenly 7 Do not use the override switch unless additional wheel speed is required for vehicle movement Use the override with caution as rearward veh...

Page 66: ...oid parking on an incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Always block the rear wheels on the dow...

Page 67: ...e vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle...

Page 68: ...educe speed and cargo weight to maintain stable driving conditions 3 NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg 4 NEVER ex...

Page 69: ...rear rack capacity The total load operator passenger accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding the m...

Page 70: ...he intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System The emissions from the exhaust of this vehicle are controlled by engine design including factory set...

Page 71: ...ice and adjustment procedures have a qualified dealer perform these operations Maintenance intervals in the following chart are based upon average rid ing conditions and an average vehicle speed of ap...

Page 72: ...sions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services Item Maintenance Interval whichever comes first Remarks Hours Calendar Miles Km Steering Pre Ride Mak...

Page 73: ...ate all fittings pivots cables etc Carburetor float bowl 50 H 6 M 500 800 Drain bowl periodically and prior to storage Shift linkage 50 H 6 M 500 800 Inspect lubricate D Steering 50 H 6 M 500 800 Lubr...

Page 74: ...M 1000 1600 Inspect for leaks Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H 12 M 1000 1600 Inspect D E Spark plug 100 H 12 M 1000 1600 Inspect replace as needed Wiring 100 H 12...

Page 75: ...use grease zerks have been provided for additional lubrication at the user s discretion Item Lube Capacity at Fluid Change Inspection Procedure Engine Oil PS 4 PLUS Performance Synthetic 2W 50 2 qt 1...

Page 76: ...may need to be changed more frequently if POLARIS oil is not used Always use 2W 50 oil Follow the manufacturer s recommenda tions for ambient temperature operation See page 126 for the part num bers...

Page 77: ...e If the oil level is over the full safe mark change the oil immediately 1 Position the vehicle on a level surface 2 Start the engine Allow it to idle for 20 30 seconds Stop the engine 3 Remove the di...

Page 78: ...rain plug The sealing sur faces on drain plug and crank case should be clean and free of burrs nicks or scratches 8 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 9 Disconnect the lower oil...

Page 79: ...n additional 1 2 turn 16 Approximately one cup of engine oil will remain in the crankcase To drain remove the drain plug on the lower right side of the crank case 17 Reinstall the drain plug The seali...

Page 80: ...ely 2 5 cm from the oil tank between the end of the oil tank vent fitting and the vent line s pressure relief slit 2 Start the engine Allow it to idle for 10 20 seconds 3 Remove the vent line clamp If...

Page 81: ...ransmission See page 126 for the part numbers of POLARIS products The fill plug is located on the left side of the ATV under the rear fender behind the wheel The drain plug is located on the right sid...

Page 82: ...der the gearcase 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug Torque to 20 25 ft lbs 27 34 Nm 5 Add 32 oz 948 ml of the recommended oil 6 Reinstall th...

Page 83: ...se of other fluids may result in improper operation of components See page 126 for the part numbers of POLARIS products Maintain the fluid level at the bottom of the fill hole threads See below for ca...

Page 84: ...10 ft lbs 11 14 Nm Fluid Change 1 Position the vehicle on a level surface 2 Remove the fill plug 3 Place a drain pan under the demand drive unit 4 Remove the drain plug Allow the fluid to drain compl...

Page 85: ...awn back up from the bottle past the pres sure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and ma...

Page 86: ...nt The recovery bottle is located on the left side of the vehicle 1 Remove the left side panel See page 86 2 Maintain the coolant level between the minimum and maximum marks on the bottle when the flu...

Page 87: ...Escaping steam can cause burns Never remove the pressure cap while the engine is warm or hot Always allow the engine to cool before removing the pressure cap 1 Open the front box cover 2 Remove the a...

Page 88: ...verfill The following checks are recommended 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 ade...

Page 89: ...sition 3 Tie a length of string between two stands as shown in the illustration Position the stands so that the string is flush with the side of the rear tire If available you may use a long straight...

Page 90: ...ide panel near the rear cab With a firm motion pull the panel outward to disengage the side panel from the grommet Pull the panel downward and rearward to remove it 3 When reinstalling side panels ali...

Page 91: ...m mended tire type size and pressure Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 mm or less Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retenti...

Page 92: ...Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure...

Page 93: ...type pre filter from the main filter Wash the pre filter in soapy water then rinse and let dry 5 Reinstall the pre filter over the main filter Install a new main fil ter if needed 6 Reinstall the fil...

Page 94: ...ently through the filter in the direction of the arrow to check for clog ging Replace a damaged or clogged filter 4 Check the hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reins...

Page 95: ...are fuses are provided in the rear storage box 1 Open the front box cover 2 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage 3 Close the front...

Page 96: ...touch a lamp clean it with denatured alcohol 1 Remove the two screws on the lower front corners of the headlight pod 2 Remove the screw from the rear of the pod 3 Lift the pod slightly while depressi...

Page 97: ...n the headlight switch to high beam 4 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 Include rider weight on the...

Page 98: ...ing harness 5 Use a small screwdriver to remove the o rings from the headlight mounting tabs 6 Pull the headlight housing up to release it from the locking tabs 7 Lift the adjusting knob up to remove...

Page 99: ...tall the harness assembly into the headlight assembly 4 Turn the headlight harness clock wise to secure the headlamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back...

Page 100: ...after the engine has been warmed up and the vehicle has been driven at higher speeds Immediately check the spark plug for correct color See page 97 CAUTION A hot exhaust system and engine can cause b...

Page 101: ...hould not be flaky and white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carbu retion adjustments Wet Fouled Spark Plug The wet fouled insulator ti...

Page 102: ...er are non adjust able Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Tip Accessory spring...

Page 103: ...r death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height...

Page 104: ...1800 m and temperatures below 40 degrees F 4 degrees C Continuous operation of the engine without proper jetting when required can cause poor performance overheating or PVT or engine damage See your...

Page 105: ...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 While adjusting...

Page 106: ...ry the air box and replace the filter with a new filter 3 Turn the fuel valve off 4 Remove the spark plug 5 Loosen the carburetor drain screw 6 Turn the engine over several times using the electric st...

Page 107: ...rge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine 4 Quickly squeeze and relea...

Page 108: ...peeds 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 following respons...

Page 109: ...range is 1 2 25 This difference in gearing affects the oper ation of the PVT especially at speeds less than 7 MPH 11 km h due to the system s dependence on engine speed For example when operating at...

Page 110: ...the drain plug Allow the water to drain completely Rein stall the drain plug 3 Start the engine Place the transmission in PARK 4 Apply varying throttle for 10 15 seconds to expel the moisture and air...

Page 111: ...oduce explosive gases Keep sparks flame cigarettes etc away Ventilate when charging or using in an enclosed space Always shield eyes when working near batteries KEEP OUT OF REACH OF CHILDREN Your ATV...

Page 112: ...sconnect the black negative battery cable first 5 Disconnect the red positive battery cable last 6 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spi...

Page 113: ...tions and securely installed Route the tube away from the frame and vehicle body to prevent contact with electrolyte WARNING Battery gases could accumulate in an improperly installed vent tube and cau...

Page 114: ...ining battery charge by using a POLARIS Battery 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...

Page 115: ...e 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 st...

Page 116: ...ndard 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...

Page 117: ...to contact the vehicle The best and safest way to clean your POLARIS vehicle is with a gar den hose and a pail of mild soap and water 1 Use a professional type washing cloth cleaning the upper body f...

Page 118: ...ler to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fittings immediately after washing Allow the engine to run for a while to evaporate any wat...

Page 119: ...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 periodical...

Page 120: ...llow the instructions on the container for the recom mended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits from pistons rings valves and exhaust system...

Page 121: ...el or tilted slightly rearward 2 Remove the spark plug Rotate the piston to BDC and pour two ounces 59 ml of engine oil into the cylinder 3 Reinstall the spark plug Torque to specification 4 Apply die...

Page 122: ...slightly off the ground Be sure the storage area is well ventilated Cover the vehicle with a genuine POLARIS cover Do not use plastic or coated materials They do not allow enough ventilation to preven...

Page 123: ...ce the transmission in PARK 3 Lock the parking brake 4 Secure the fuel cap and oil cap 5 Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope Do not attach ti...

Page 124: ...Shift the transmission to low range and carefully use fast aggressive throttle application to engage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over larg...

Page 125: ...on Fouled or defective spark plug s Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer...

Page 126: ...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 Throttle release switch mal...

Page 127: ...ition 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 repl...

Page 128: ...in 218 cm Overall Width 48 in 122 cm Overall Height 48 in 122 cm Wheelbase 57 in 145 cm Ground Clearance 11 in 28 cm Minimum Turning Radius 82 in 208 cm unloaded Fuel Capacity 4 25 gal 16 l Engine Oil...

Page 129: ...ear 25x10 12 5 psi Brakes Front Single Control Hydraulic Disc Brakes Rear Single Control Hydraulic Disc Brake Auxiliary Foot Activated Hydraulic Disc Brake Parking Hydraulic lock all wheel Headlight 1...

Page 130: ...72277 Premium Demand Drive Hub Fluid 9 5 l Coolant 2871323 60 40 Coolant gal 3 8 l 2871534 60 40 Coolant qt 95 l Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 2871322 Premium...

Page 131: ...anty period through a POLARIS 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 regi...

Page 132: ...parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Warranty app...

Page 133: ...orkmanship 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...

Page 134: ...ur 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 addit...

Page 135: ...any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was...

Page 136: ...u receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above...

Page 137: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty is the responsibility of the vehicle owner This emissions limited...

Page 138: ...by a defect in material or workman ship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine...

Page 139: ...section of your manual to your dealer each time your vehi cle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE MILES KM OR HOURS TECH...

Page 140: ...136 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 141: ...137 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 142: ...eel Care 115 Cleaning and Storage 113 118 Clothing 9 Clutching 125 C Cold Weather Operation 48 Consumer Product Safety 7 Coolant Bottle 82 Coolant Radiator 83 Cooling System 81 83 Corrosion Removal Ch...

Page 143: ...Hub Tightening 87 I Idle RPM Adjustment 100 Immersion Maintenance 102 Instrument Cluster 36 41 J Jetting Chart 125 K Key Switch 27 K Turn 56 57 L Lights 92 95 Headlight Housing 94 Headlight Lamp 92 Hi...

Page 144: ...to Inspect 11 S Safety Warnings 10 21 Frozen Bodies of Water 20 Handling Gasoline 11 Hot Exhaust Systems 21 Improper Cargo Loading 19 Improper Hill Climbing 15 Improper Tire Maintenance 18 Jumps and S...

Page 145: ...s 87 88 Wheel Installation 88 Wheel Nut Torque 88 Wheel Removal 87 Toe Alignment 85 Towing Loads 65 Trail Etiquette 46 Training 7 Transmission 33 Transmission Oil 77 78 Transporting the ATV 119 Tread...

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