Polaris 600 Dragon SP Owner'S Manual Download

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149

INDEX

Accessories

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Adjustments

102-117

. . . . . . . . . . . . . . . . . . . . . . . .

Age Restrictions

. . . . . . . . . . . . . . . . . . . . . . . . . .

Air Filter

118-119

. . . . . . . . . . . . . . . . . . . . . . . . . . .

All Wheel Drive

48-49

. . . . . . . . . . . . . . . . . . . . . . .

Auxiliary Brake

42, 105

. . . . . . . . . . . . . . . . . . . . .

AWD

48-49

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery

134-136

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery (Conventional)

133

. . . . . . . . . . . . . . . . . . .

Battery Charging (Sealed Battery)

135-136

. . . . . .

Battery Fluid (Conventional)

134

. . . . . . . . . . . . . .

Battery Installation

135

. . . . . . . . . . . . . . . . . . . . . .

Battery Removal

134

. . . . . . . . . . . . . . . . . . . . . . . .

Battery Storage

135, 140

. . . . . . . . . . . . . . . . . . . . .

Belt Life

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake Lever

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brakes

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Break in Period (2-Cycle)

. . . . . . . . . . . . . . . . . .

Break in Period (4-Cycle)

. . . . . . . . . . . . . . . . . .

Break-In Period

56-57

. . . . . . . . . . . . . . . . . . . . . .

Breather Filter/Hose

119

. . . . . . . . . . . . . . . . . . . . .

Camber and Caster

107

. . . . . . . . . . . . . . . . . . . . . .

Carburetor

109-110

. . . . . . . . . . . . . . . . . . . . . . . . . .

Choke

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cleaning and Storage

137-140

. . . . . . . . . . . . . . . .

Cleaning the ATV

137

. . . . . . . . . . . . . . . . . . . . . . .

Cold Weather Operation (4-Cycle)

. . . . . . . . . . .

CONTROLS

37-47

. . . . . . . . . . . . . . . . . . . . . . . .

Coolant Level

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Counter Balance Oil Check - 400 Engines

. . . . .

Counterbalance Oil Change - 400 Engines

. . . . .

Cylinder Head/Cylinder Base Fastener

115

. . . . . . .

Diagnostic Mode

. . . . . . . . . . . . . . . . . . . . . . . . .

Disengaging Wheel Hubs

. . . . . . . . . . . . . . . . . .

Drive Chain

115

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving Downhill

. . . . . . . . . . . . . . . . . . . . . . . .

Driving in Reverse

. . . . . . . . . . . . . . . . . . . . . . .

Driving on Slippery Surfaces

. . . . . . . . . . . . . . .

Driving Over Obstacles

. . . . . . . . . . . . . . . . . . . .

Driving Procedures

. . . . . . . . . . . . . . . . . . . . . . .

Driving Safely

63-73

. . . . . . . . . . . . . . . . . . . . . . .

Driving Through Water

. . . . . . . . . . . . . . . . . . . .

Driving Uphill

. . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical Switches

. . . . . . . . . . . . . . . . . . . . . . .

Engaging Wheel Hubs

. . . . . . . . . . . . . . . . . . . .

Engine Cooling System

99-101

. . . . . . . . . . . . . . .

Engine Fogging

139

. . . . . . . . . . . . . . . . . . . . . . . .

Engine Oil Check

. . . . . . . . . . . . . . . . . . . . . . . .

Equipment Modifications

. . . . . . . . . . . . . . . . . .

FEATURES

48-55

. . . . . . . . . . . . . . . . . . . . . . . . .

Filter Systems

118-119

. . . . . . . . . . . . . . . . . . . . . . .

Front Brake

104

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front Gearcase Oil Change

. . . . . . . . . . . . . . . . .

Front Gearcase Oil Check

. . . . . . . . . . . . . . . . . .

Front Wheel Hub Tightening

114

. . . . . . . . . . . . . .

Fuel Filter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Safety

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Stabilizer

138

. . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Tank

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel Valve

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Gear Selector

. . . . . . . . . . . . . . . . . . . . . . . . . . .

Gearcase Oil Fill Chart

. . . . . . . . . . . . . . . . . . . .

Handlebars

108

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hauling Cargo

61-62

. . . . . . . . . . . . . . . . . . . . . . . .

Headlight Adjustment - Trail Blazer

121

. . . . . . . . .

Headlight Housing Replacement - Gen IV

124

. . . .

Headlight Lamp Replacement - Gen IV

122

. . . . . .

Headlight Lamp Replacement - Scrambler

120

. . . .

Headlight Lamp Replacement - Trail Blazer

121

. . .

Helmet

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

High Beam Adjustment - Gen IV

123

. . . . . . . . . . .

High Beam Adjustment - Scrambler

120

. . . . . . . . .

High Range

131

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hour Meter

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Indicator Lamp Replacement

125

. . . . . . . . . . . . . .

Indicator Lights

. . . . . . . . . . . . . . . . . . . . . . . . .

Instrument Cluster

51-55

. . . . . . . . . . . . . . . . . . . .

K-turn

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Light Switches

. . . . . . . . . . . . . . . . . . . . . . . . . .

Lights

120-125

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low Range

131

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

Lubrication Recommendations

80-98

. . . . . . . . . . .

Main Switch

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE AND LUBRICATION

75-140

Maintenance Record

. . . . . . . . . . . . . . . . . . . . . .

Making Turns

. . . . . . . . . . . . . . . . . . . . . . . . . . .

NOISE CONTROL SYSTEM

. . . . . . . . . . . . .

Odometer

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Change

86-90

. . . . . . . . . . . . . . . . . . . . . . . . . .

Oil Filter Change

86-90

. . . . . . . . . . . . . . . . . . . . .

Summary of Contents for 600 Dragon SP

Page 1: ...Owner s Manual Vehicle Maintenance and Safety 2003 ATV for Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age ...

Page 2: ...WARNING The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm ...

Page 3: ...ated a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustries com owner ...

Page 4: ...ing Polaris Industries Inc reserves the right to make product changes and improvements that may affect illustrations or explanations No part of this manual shall be reproduced or used without the written permission of Polaris Industries Inc Copyright 2002 Polaris Industries Inc All Rights Reserved Printed in the U S A ...

Page 5: ...cle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer MSD Technici...

Page 6: ...4 ...

Page 7: ...TY 7 CONTROLS 37 FEATURES 48 OPERATION 56 NOISE EMISSION CONTROL SYSTEM REGULATION 74 MAINTENANCE AND LUBRICATION 75 POLARIS RECOMMENDED PRODUCTS 141 TROUBLESHOOTING 142 WARRANTY 146 INDEX 149 NOTE Illustrations used in this manual are for general representation only Your model may differ ...

Page 8: ...essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided 2 1 31XX 3 Frame VIN Engine Serial ...

Page 9: ...olaris dealer you can request this free safety training from any authorized Polaris dealer A Polaris ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure...

Page 10: ...on your ATV or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine CAUTION NOTE A note will alert you to important information or instructions A caution indicates a situati...

Page 11: ...ves boots a long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating an ATV S Never operate at excessive speeds Travel at speeds appropriate for the terrain visibility and operating conditions and your experience S Never attempt wheelies jumps or other stunts S Always inspect your ATV before each use to make sure it s in safe operating condition Always...

Page 12: ... attempt to turn the ATV around on any hill until you ve mastered on level ground the turn ing technique outlined in this manual Avoid crossing the side of a steep hill when possible S Always use proper procedures if you stall or roll backwards while climbing a hill To avoid stalling maintain a steady speed when climbing a hill If you stall or roll backwards follow the special pro cedure for braki...

Page 13: ...e or accidental starting FOR MORE INFORMATION ABOUT ATV SAFETY call the Con sumer Product Safety Commission at 1 800 638 2772 or call Polaris at 1 800 342 3764 Equipment Modifications We are concerned for the safety of our customers and for the general public Therefore we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the veh...

Page 14: ...he operating techniques described in the owner s manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Failure to follow the age recommendations for this ATV WHAT CAN HAPPEN Severe injury and or death could occur if a child under the minimum age recommendation operates an ATV Even though a child may be within the r...

Page 15: ...s the operator s ability to balance and control the ATV which could cause an accident and injury to the operator and or passenger HOW TO AVOID THE HAZARD Never carry a passenger The purpose of the long seat is to allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING ...

Page 16: ...WHAT CAN HAPPEN ATV tires are designed for off road use Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control accident and or injury HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement If it s unavoidable travel slowly and avoid sudden turns or stops WARNING ...

Page 17: ... roads or highways WHAT CAN HAPPEN The ATV could collide with another vehicle HOW TO AVOID THE HAZARD Never operate the ATV on any public street road or highway including dirt and gravel roads In many states it s illegal to operate ATVs on public streets roads and highways WARNING ...

Page 18: ...eases the risk of a severe head injury or death in the event of an accident Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident 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 WARNI...

Page 19: ... while operating an ATV could result in an accident causing severe injury or death HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV POTENTIAL HAZARD Operating the ATV at excessive speeds WHAT CAN HAPPEN Excessive speed increases the operator s chance of losing control of the ATV which can result in an accident HOW TO AVOID THE HAZARD Always operate the ATV at...

Page 20: ...ARD Attempting wheelies 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 wheelies jumps or other stunts Avoid exhibition driving WARNING ...

Page 21: ...ocedures and schedules described in the owner s manual POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could come into contact with the rear w...

Page 22: ...V on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions WARNING ...

Page 23: ...ly 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 necessary to control the ATV on such terrain Always use extra caution on rough slippery or loose terrain WARNING ...

Page 24: ...bed in the owner s manual Practice turning at slow speeds before attempting to turn at faster speeds Never turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle may overturn HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities Never operate the ATV on hills steeper than 25_ Practice on smaller hills before at...

Page 25: ...er s manual Always check the terrain carefully before ascending any hill Never operate the ATV on hills steeper than 25_ Never climb hills with excessively slippery or loose surfaces Shift your weight forward Never open the throttle suddenly while traveling uphill 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...

Page 26: ...raveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 68 Always check the terrain carefully before you descending a hill Shift your weight backward Never travel down a hill at high speed Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill ...

Page 27: ...rn 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 69 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 the...

Page 28: ...y stopped apply the auxiliary rear brake as well then lock the parking brake If the ATV begins rolling backwards Keep weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is p...

Page 29: ... as rocks and fallen trees when possible If unavoidable use extreme caution and always follow proper procedures as outlined in the owner s manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN Skidding or sliding can cause loss of control If the tires regain traction unexpectedly the ATV could overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice travel slowly and use extra cauti...

Page 30: ...ight 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 If necessary apply them several times to let friction dry out the pads POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPPEN The ATV could coll...

Page 31: ...cribed in the owner s manual supplement POTENTIAL HAZARD Operating the ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause changes in handling 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 gen...

Page 32: ...argo or pulling a trailer Allow a greater distance for braking Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See page 61 POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the ATV and or the operator fall through the ice HOW TO AVOID THE HAZARD Never operate the ATV on a frozen body of water If yo...

Page 33: ...sons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control which could result in severe injury or death CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire WARNING WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in...

Page 34: ...l neveractivate override button with open throttle DPARKING BRAKE may relax when used for more than 5 minutes When parking on grades leave shift in for ward WARNING 7079085 This ATV may exceed the perfor mance of other ATVs you may have ridden in the past This category S Sport ATV is a high performance vehicle for off road use only in sport type recreation and competitive use by operators with adv...

Page 35: ...or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered carried as low as possible and firmly secured to the racks with dual racks load distribution 1 3 front 2 3 rear is best For stability on rough or hilly terrain reduce speed and cargo Do not block headlight Be careful if load extends over the side of the rack Read Owner s Manual for mor...

Page 36: ...tch Doing so can cause part failure possible imbalance and excessive engine RPM which can result in serious injury or death NO STEP 7078689 DSpecific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40_ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters 7079901 WARNING DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tip...

Page 37: ...mited Reverse override is controlled by the override switch See your Owner s Manual OVERRIDE SWITCH 7079906 AWD Models 2WD Models Chain Freeplay Is Important Adjust Freeplay to 3 16 3 8 DO NOT Overtension See Owner s Manual Torque Nut on Eccentric Bolts To 30 Ft Lbs For models without a hitch To 60 Ft Lbs For models with a hitch 7078572 WARNING Pushing reverse override button may cause sudden in c...

Page 38: ...nstitute label ANSI z90 1 or the Snell Memorial Foundation label 2 Eye Protection Do not depend on sunglasses for proper eye protection A pair of goggles or a helmet face shield offer the best protection for your eyes They should be kept clean and be of shatterproof design bearing the markings z2 1 or VESC 8 3 Gloves Off road style gloves with knuckle pads are the best for comfort and protection 4...

Page 39: ...osition Release the key when the engine starts NOTE Turn off the main switch to end all electrical power to the vehicle including the cooling fan and lights Engine Stop Switch 3 The engine will not start or run when the switch is in its off position Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency To stop the engine slide the stop switch either r...

Page 40: ...rottle 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 replace it with any after market throttle mechanisms WARNING Do not start or operate an ATV with sticking or improperly operating throttle controls which could cause an accident and lead to severe injury or death Always contact your dealer for...

Page 41: ...el the ATV must be on level ground with the handlebars straight If the fluid level is low add DOT 3 brake fluid only See page 141 for the part numbers of Polaris recommended products Operating the ATV on streets or roads especially in darkness could result in an accident and serious injury or death Your ATV is not equipped with highway approved lights It s designed for and must be used for off roa...

Page 42: ...er travel and master cylinder fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must be corrected before riding Contact your dealer for proper diagnosis and repairs 1 Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never operate the A...

Page 43: ...king brake may relax if left on for a long period of time Al ways block the wheels to prevent rolling S Always block the wheels on the downhill side of the ATV if leaving it parked on a hill Another option is to park the ATV in a sidehill position S Never depend on the parking brake alone if the ATV is parked on a hill Always block the wheels to prevent rolling Operating the ATV while the parking ...

Page 44: ...t skidding Check the brake fluid level frequently for the auxiliary brake system The reservoir is located under the seat or near the foot brake Maintain the fluid level between the maximum and minimum marks Aggressively applying the rear 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 aggressiv...

Page 45: ...ply is exhausted NOTE There s about a 7 to 10 mile 11 2 to 16 km range on reserve gas Always refill the gas tank as soon as possible after using the reserve supply Always return valve to on position after refueling Fuel Tank The fuel tank filler cap 2 is located directly below the handlebar Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Refer to your ow...

Page 46: ...verfill the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of con sciousness or death in a short time S Turn the fuel valve off whenever the ATV is stored or parked The engine exhaust from this...

Page 47: ...he front of the vehicle Tank capacity is two quarts 1 9 l Mixing brands or using a non recommended oil may cause serious engine damage We recommend the use of Polaris Premium Synthetic 2 cycle oil for your 2 cycle Polaris ATV Never substitute or mix oil brands To avoid serious engine damage always top off the oil level when refueling CAUTION 1 ...

Page 48: ...ft linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems Belt Life To extend belt life use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time 1 H N R H L N R H L N R P H N P L R Shifting gears with the engine speed above idle or while the vehicle is m...

Page 49: ...rt and restores compression for starting 1 Position the vehicle on a level surface and engage the parking brake See page 41 2 Shift the transmission to Neutral 3 Grasp the recoil starter rope handle tightly and pull slightly until the starter mechanism engages 4 Pull the rope abruptly to start the engine 1 Extending the starter rope too far will cause damage to the recoil assembly Do not extend th...

Page 50: ...vehicle may remain in Demand 4 Drive Engaging Wheel Hubs The Demand 4 Drive 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 front hubs are moving the hubs will not disengage unti...

Page 51: ...peed is somewhat restricted Disengage the hubs by stopping shifting to reverse and backing for a short distance Then proceed in forward again NOTE If the hubs remain engaged after following this procedure return the ATV to your dealer for service To continue using AWD in reverse activate the override switch and the Demand 4 Drive switch See page 37 Operating with only one front hub engaged could r...

Page 52: ...g verify the function of all indicator lights each time the ATV is used NOTE The taillight is on whenever the main switch key is on Turn the key off to prevent battery drain 1 Transmission Neutral Indicator green 2 Transmission Low Gear Indicator blue grey 3 Transmission Reverse Indicator yellow 4 Oil Warning red On 2 cycle models this light indicates a low oil level 5 High Temp Warning red This l...

Page 53: ... page 37 for additional information 1 Rider Information Center 2 Speedometer needle in addition to depicting vehicle speed this needle will flash to signal a fault condition 3 Speedometer 2 3 1 CAUTION Washing the ATV with a high pressure washer may cause water to enter the instrument cluster and cause damage to the electronic components Wash the ATV by hand or with a garden hose using mild soap D...

Page 54: ...wever also indicate that the transmission switch needs repair 2 High Engine Coolant Temperature Do not continue to operate the ATV is this warning appears or serious engine damage could result 3 Hour Meter 4 Service Interval Miscellaneous Service Warnings 5 Low Battery and Over Voltage This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged Drivi...

Page 55: ...the options the machine cannot be in reverse Mode 1 Odometer The odometer records the miles traveled by the ATV Mode 2 Trip Meter The trip meter records the miles 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 NOTE In the Rider Information Center the trip ...

Page 56: ... reminder that the periodic maintenance is due To set the hours press and hold the mode override button until the wrench icon flashes When it begins to flash release the button The setting will increase by one hour each time the button is pressed Pressing and holding the button will allow the numbers to escalate much faster When the desired time increment is displayed release the button and wait f...

Page 57: ...efly Use the mode reverse override button to toggle through the diagnostic screens The first screen 1 displays battery voltage The second screen 2 provides full diagnostics for the entire oil pressure electrical circuit Along with the letters PrSSr there will be a box on the left side If the box is high the pressure is normal If the box is low the pressure is low Screen three 3 is the tachometer f...

Page 58: ...owly at first Select an open area that will allow room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 58 After the first tank of pre mixed fuel has been used verify that the oil level in the oil tank has dropped indicating that the oil ...

Page 59: ...perating range 1 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 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 58 6 Pull only light loads 7 During the break in period change both the oil and th...

Page 60: ...htness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain Check condition and slack refer to drive chain adjustment section lubricate when needed 9 Air cleaner element Check for dirt clean or replace 10 Steering Check for free operation noting any unusual looseness in any area 11 Loose parts Visually inspect vehicle for any damaged components or loose nuts bo...

Page 61: ...on key past the on position to engage the starter Activate the starter for a maximum of five seconds releasing the key when the vehicle starts If the engine does not start release the starter and wait five seconds Then activate the starter for another five seconds Repeat this procedure until the engine starts 7 If the engine slows or stops position the choke knob half way in to allow proper engine...

Page 62: ...the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 5 Release the throttle lever immediately after the engine starts If the engine does not start and all conditions are favorable change the spark plug and try again Cold Weather Operation for 4 Cycle Engines If the ATV is used year round check the oil level frequently A rising oil level could indic...

Page 63: ...n the front and 2 3 on the rear and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Maximum Towing Capacities Refer to your owner s manual supplement for model specific towing capacities When towing reduce the rear rack cargo load capacity by the amount of trailer tongue weight Never tow any trailer on a grade steep...

Page 64: ...SECURED BEFORE OPERATING Un secured loads can create unstable operating conditions which could result in loss of control of the vehicle S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be cen tered securely fasten load and operate with extra caution Al ways attach the tow load to the hitch point designated for your vehicle S HEAVY LOADS CAN CAUSE BR...

Page 65: ...t to warm up then shift the transmission into gear 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amount of throttle opening 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces ...

Page 66: ...ection 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 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 sha...

Page 67: ... in the direction of the skid and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engagedcan assistin controlling the vehicle in slippery areas Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of co...

Page 68: ...ATV begins rolling backwards Keep your weight uphill Never apply engine power Never apply the auxiliary rear brake while rolling backwards Apply the single lever brake gradually When fully stopped apply the auxiliary rear brake as well and then lock the parking brake Dismount on uphill side or to either side if ATV is pointed straight uphill Turn the ATV around and remount following the procedure ...

Page 69: ...ward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions NOTE If the vehicle begins to tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately 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 ...

Page 70: ... vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing using the single brake lever NOTE Familiarize yourself with operation of the auxiliary rear brake pedal for additional braking in the event of normal service brake loss Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill WARNING ...

Page 71: ...ding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward 6 Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill 7 Restart the engine with the transmission still in forward 8 Release the parking brake and proceed slowly controlling speed with the br...

Page 72: ... and rear gearcases and all grease fittings NOTE Avoid operating the vehicle through deep or fast flowing water If you cannot avoid water that exceeds the recommended maximum depth go slowly balance your weight carefully 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...

Page 73: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches 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 WARNING ...

Page 74: ... increased Do not operate at wide open throttle Open the throttle just enough to maintain a desired speed 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 vehic...

Page 75: ...d parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 1 Place the transmission in gear 2 Set the parking brake 3 Always block the rear wheels on the downhill side See illustration 4 Shut off the fuel supply ...

Page 76: ...ARE NOT LIMITED TO THE FOLLOWING 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance USFS Approved Spark Arrestor Mos...

Page 77: ...ing charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use such as operation in wet or dusty areas should be inspected and serviced more frequently Inspect clean lubricate adjust and replace parts as necessary When inspection reveals the need for replacement parts use genuine Polaris parts available from your...

Page 78: ...r Pre Ride Pre Ride Inspect clean Coolant level Pre Ride Pre Ride Replace coolant every two years Fuel and oil tanks Pre Ride Pre Ride Fill to proper levels Throttle Pre Ride Pre Ride Check operation Lights Pre Ride Pre Ride Check operation Engine stop switch Pre Ride Pre Ride Check operation Drive chain Pre Ride Pre Ride Check condition slack Steering Pre Ride Pre Ride Check for free operation Ai...

Page 79: ...10 hrs Monthly Inspect periodically Front and rear gearcase oil shaft drive 100 hrs Monthly Check monthly change annually Engine cylinder head and cylinder base fasteners 25 hrs 3 months Inspect re torque required at first service only General lubrication 50 hrs 3 months Lubricate all fittings pivots cables etc L Engine oil level oil change 4 Cycle 100 hrs 1000 miles 6 months Check level daily bre...

Page 80: ...k monthly Shift linkage 50 hrs 6 months Inspect adjust J Drive belt 50 hrs 6 months Inspect replace as needed Steering 50 hrs 6 months Inspect daily lubricate Front suspension 50 hrs 6 months Inspect lubricate tighten fasteners Rear suspension 50 hrs 6 months Inspect tighten fasteners Drive chain s 50 hrs 6 months Inspect daily adjust and lu bricate if needed L Spark plug 100 hrs 12 months Inspect...

Page 81: ...2 months Inspect clean Engine mounts 100 hrs 12 months Inspect J L Valve clearance 4 Cycle 100 hrs 12 months Inspect adjust J Oil filter 2 Cycle 100 hrs 12 months Replace J Shift selector box H L R 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change every two years J Front wheel bear ings 2WD 300 hrs 36 months Inspect replace as needed L Idle speed As required...

Page 82: ...ill oil tank See page 45 As needed when refueling 4 Cycle Engine Polaris Premium 4 Synthetic 0W40 Add to proper level on dip stick Check level daily Brakes DOT 3 fluid only Maintain level between fill lines See page 39 As required change every two years or 200 hours Drive chain s O ring chain lube or SAE 80 90 Lubricate as often as re quired Before each ride in wet conditions As required 1 Transmi...

Page 83: ...81 MAINTENANCE AND LUBRICATION Lubrication Recommendations 4 1 5 2 2 3 ...

Page 84: ...ly and change annually 10 Rear Axle Bearing L Grease Locate fittings and grease Every 3 months or 50 hours 11 Swing Arm Bushings L Grease Locate fittings on swing arm and grease with grease gun Monthly or at 20 hours 12 Upper Con trol Arms L Grease Locate fittings and grease Semi annually 13 Lower Con trol Arms L Grease Locate fittings and grease Semi annually 14 Rear Wheel Hub Bearing Car rier L ...

Page 85: ...83 MAINTENANCE AND LUBRICATION Lubrication Recommendations 7 9 8 6 4 O clock position 6 11 10 12 14 15 13 13 ...

Page 86: ...NCE AND LUBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks 10 hrs 20 hrs 50 hrs 100 hrs ...

Page 87: ...air cooled 2 cycle engines Polaris Premium 2 cycle oils will readily mix with each other but do not mix Polaris Premium 2 cycle oils with any other brand of oil including our Nature Oil Biodegradable oil Their incompatibility could result in engine damage See page 141 for the part numbers of Polaris recommended products Premium Gold Synthetic 2 Cycle Oil Your vehicle has been primed with Premium G...

Page 88: ...is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation Oil and Filter Change 4 Cycle Engines With External Oil Tank The recommended oil change interval is 100 hours 1000 miles or every six months whichever comes first Suggested break in oil change is at 20 hours 200 m...

Page 89: ...rain plug NOTE The sealing surfaces on the drain plug and on the oil tank should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug Torque to 14 17 ft lbs 19 23 Nm 8 Disconnect the lower oil delivery hose Remove the fitting C from the oil tank Clean the fitting screen Reinstall the fitting screen torquing to 14 17 ft lbs 19 23 Nm Reattach oil line Torque hose clamp E to 25 in...

Page 90: ...s on the drain plug and crankcase should be clean and free of burrs nicks or scratches 15 Remove the dipstick 2 and add the amount of oil indicated in your owner s manual supplement Reinstall the dipstick NOTE If the sump is not drained add about 1 3 4 quarts initially 16 Place the gear selector in neutral and set the parking brake 17 Start the engine and let it idle for one to two minutes Stop th...

Page 91: ...lug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall the drain plug and torque to 14 ft lbs 19 Nm 8 Place shop towels beneath the oil filter Using an oil filter wrench turn the filter counterclockwise to remove 9 Using a clean dry cloth clean the filter sealing surface on the crankcase 10 Lubricate the gasket on the new filter with a film of engine oil Check to make s...

Page 92: ...p with 2 quarts 1 9 l of Polaris Premium 4 synthetic oil 13 Place the gear selector in neutral and set the parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Recheck the oil level and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used filter and oil properly ...

Page 93: ...check the oil level NOTE The transmission fill plug is located on the right side of the machine behind either the propshaft shield or footwell 2 Use the gearcase oil fill chart and the following illustration to determine correct fluid levels NOTE When adding oil use Polaris Premium Synthetic Gearcase Lubricant See page 141 for the part numbers of Polaris recommended products Gearcase Oil Fill Char...

Page 94: ...ss the fill plug 2 Remove the fill plug 3 Remove the transmission drain plug located on the bottom left hand side and drain the oil Catch and discard used oil properly 4 Clean and reinstall the drain plug torque to 14 ft lbs 19 Nm 5 Add the correct amount of Polaris Premium Synthetic Gearcase Lubricant Refer the the gearcase oil fill chart on page 91 for proper oil levels 6 Check for leaks 7 Reins...

Page 95: ... check the level Add the proper lubricant as required to bring level into the safe operating range NOTE When adding oil use Polaris Premium Synthetic Gearcase Lubricant See page 141 for the part numbers of Polaris recommended products Transmission Oil Change 2x4 Models 1 Place a drain pan beneath the transmission oil drain plug area 2 Loosen the jam nut A 3 Turn the adjuster bolt B in to allow the...

Page 96: ...for leaks Transmission Oil Change Sportsman 1 Remove the fill plug dipstick 2 Remove the transmission drain plug and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug 4 Add 32 oz 948 ml of Polaris Premium Synthetic Gearcase Lubricant to the full mark on the fill plug dipstick Maintain the oil level in the safe operation range 1 NOTE See page 141 for the part nu...

Page 97: ...and check the oil level The level should be maintained at the bottom of the fill plug threads Type C The lubricant level in this type of gearcase cannot be checked Periodically drain the oil and refill Front Gearcase Oil Change 1 Position the vehicle on a level surface and remove the fill plug 1 2 Place a drain pan beneath the gearcase remove the gearcase drain plug and drain the oil 3 Clean and r...

Page 98: ...TE See page 141 for the part numbers of Polaris recommended products NOTE Do not add lubricant to the bottom of the fill plug threads Rear Gearcase Oil Change 1 Remove the drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a new sealing washer Torque to 14 ft lbs 19 Nm 3 Remove the fill plug and add 10 oz 300 ml of the recommended gear lube Maintain the oil ...

Page 99: ...AE 10W30 oil 1 Remove the seat and remove the dipstick 1 2 Read the oil level If necessary add SAE 10W30 oil with a transmission fluid funnel until the oil reaches the recommended level on the dipstick 2 NOTE If overfilled the excess oil will be expelled through the vent hose 3 Reinstall the dipstick and reinstall the seat Counterbalance Oil Change 400 2 Cycle Engines Drain Locations A Counter Bal...

Page 100: ...urface 2 Start the engine and let it idle for 20 30 seconds Stop the engine 3 Remove the dipstick and wipe it dry with a clean cloth 4 Screw the dipstick completely in NOTE The dipstick must be screwed completely in to keep the angle and depth of the stick consistent 5 Remove the dipstick and read the oil level Maintain the oil level in the normal safe operating range 3 Do not overfill 1 2 ADD 8 O...

Page 101: ...st the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle Polaris rec...

Page 102: ...d Reinstall the oil cap Gen IV Using the tool provided remove the four screws securing the front rack 2 Remove the front cover 3 by placing your fingers under the front of the cover and pulling upward 2 Remove the pressure cap 3 Using a funnel slowly add coolant as necessary through the radiator filler neck 4 Replace the pressure cap and secure the front cover NOTE Use of a non standard pressure c...

Page 103: ...red in your area Oil Pump Bleeding 2 Cycle Engines 1 Fill the oil reservoir with Polaris Premium 2 Cycle Oil NOTE See page 141 for the part numbers of Polaris recommended products 2 If the oil supply line has been disconnected from the pump or if the oil reservoir and supply line have been completely run out of oil loosen the bleeder screw one full turn skip this step if conditions do not apply Al...

Page 104: ...open See your owner s manual supplement 3 Place very slight pressure on the throttle lever 2 until all freeplay is removed from the throttle cable to the point where the carb slide is just starting to rise 4 Loosen the locknut 3 Turn the adjuster in or out until all freeplay is removed from the oil pump cable the point where the oil pump arm is just starting to move off its stop The pump stop keep...

Page 105: ...y slight pressure on the throttle lever until all freeplay is removed from the throttle cable to the point where the carb slide is just starting to rise 4 Lift the boot 1 up off the adjuster sleeve 2 5 Remove the oil pump cover and loosen the cable adjuster locknut 6 Adjust the oil pump cable until the marks align 3 when the throttle slide just begins to rise 7 Tighten the locknut 8 Recheck the ad...

Page 106: ...aced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation Use Polaris DOT 3 brake fluid see page 141 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 5 Check the security and surface condition of the disc NOTE Pads should be changed wh...

Page 107: ... U S dime Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Your vehicle s auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail the rear brake can be activated by depressing the foot pedal on the inside of the right footrest The hydraulic auxiliary brake system will not need adjustment NOTE Since this is...

Page 108: ...e illustration 3 Tie an elastic string around the stands making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the vehicle 2 4 Measure the distance from the string to the rim at the front and rear of the front rim 3 Rear measurement should be 1 16 1 8 2 to 3 cm more than the front measurement NOTE If you discover i...

Page 109: ...d bolts are found see your Polaris dealer for service before operating the vehicle Camber and Caster The camber and caster are non adjustable Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster 1 either clockwise or counterclockwise to increase or decrease spring tension NOTE Accessory springs are available through your Polaris dealer 1 1 ...

Page 110: ...ct the gas tank or any other part of the machine when turned fully to the left or right 4 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 will remain at the rear bolts 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 ...

Page 111: ...e overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 2 Cycle Engines If the engine idle speed is not satisfactory and all other conditions are favorable the carburetor can be adjusted 1 Warm up the engine by running the vehicle for approximately five minutes 2 Place the transmission in gear with the parking brake applied 3 Ad...

Page 112: ...il the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 freeplay is achieved at the thumb lever NOTE While adjusting ...

Page 113: ...rward and outward to disengage the two rear tabs 3 Place your hand on top of the side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on the side panel to disengage the front upper and lower tabs 4 To reinstall the side panel align the panel tabs with the slots on the front cab Push the panel upward and forward unt...

Page 114: ...el Operating your ATV 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 ATV and in your owner s manual supplement Always use original equipment size and type when replacing tires Make sure the wheels a...

Page 115: ...l the wheel nuts and finger tighten 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart NOTE All nuts that have a cotter pin installed must be serviced by an authorized Polaris dealer Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Bolt Size Specification Fro...

Page 116: ... WARNING Operating the vehicle with worn tires will increase the possibility of skidding which could lead to loss of control and serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Use of non standard size or type of tires or improper tire inflation may adversely affect vehicle maneuverability and cause loss of control resulting in serious injury or death Ma...

Page 117: ...to rear sprocket clearance at 1 8 3 cm Regularly lubricate the drive chain with SAE 80 90 lube or an approved o ring chain spray lube See page 141 for the part numbers of Polaris recommended products Cylinder Head Cylinder Base Fastener 2 Cycle Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours Washing the drive chain w...

Page 118: ... cm deflection Use the following procedure if adjustment is required 1 Remove the chain guard if applicable 2 Loosen the chain guide 3 Loosen the two eccentric locking bolts 1 4 Loosen the caliper mounting bracket bolts located under the axle 5 Insert a pin punch 2 through the sprocket hub and into the eccentric housing Adjusting or operating the ATV with improper rear drive chain slack can result...

Page 119: ...or machines without the hitch and 45 ft lbs 61 Nm for machines with a hitch 8 Tighten the caliper mount bolts to 10 12 ft lbs 14 17 Nm 9 Remove the pin punch 10 Roll the ATV forward checking chain tension in several places around the chain NOTE The chain is adjusted correctly when the tightest portion of the chain has approximately 3 8 10mm deflection 11 Position the chain guide to allow 1 8 3mm c...

Page 120: ...in the air box 3 Tighten the clamp Do not overtighten as filter damage could occur 4 Check the cover gasket and replace if needed Be sure the cover is seated properly then snap the clips onto the cover 5 Reinstall the ATV seat Air Filter Cleaning 2 Cycle Engines NOTE Always replace the main filter when it becomes dirty In an emergency situation however you may clean the main filter if you observe ...

Page 121: ...ther Filter Hose 4 Cycle Engines with Dry Sump NOTE Refer to your owner s manual supplement to determine if your machine has a dry sump 1 Remove the clamps and pull the filter 1 out of the hoses NOTE It s not necessary to remove the lower hose from the engine 2 Inspect the filter for debris Blow gently through the filter in the direction of the arrow to check for clogging Replace if needed 3 Check...

Page 122: ...beam can be adjusted vertically 1 Position the ATV on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim on the wall The most intense part of the headlight beam should...

Page 123: ...t Trail Blazer 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a flat wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn on the headlight 4 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed 8 20 3 cm below the ...

Page 124: ... depressing the tabs 4 Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the indicator light harness and remove the pod cover 5 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 6 Grasp the bulb housing and turn counterclockwise to remove lamp 7 Apply dielectric grease to the light bulb socket before installing the ...

Page 125: ...hile depressing the tabs 5 Remove the screw in the back of the headlight pod 6 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 7 Start the engine and turn the headlight switch to high beam 8 Observe the headlight aim on the wall The most intense part of the headlight beam should be aimed two inches 5 1 cm below the mark placed on th...

Page 126: ...the indicator light harness and remove the pod cover 4 Unplug the headlamp from the wiring harness 5 Remove the o ring 1 from the headlight pivot pins 6 Pull the headlight housing up to release from the locking tabs 7 Lift the adjusting knob up to remove from the locking tabs 8 Carefully pull the assembly up and out of pod 9 Reverse the steps to install the new housing and reassemble the pod NOTE ...

Page 127: ...new lamp 3 Test the taillight brakelight to see that it s working 4 Reinstall the gasket and lens cover Indicator Lamp Replacement 1 Remove the instrument panel if necessary to access the back of the indicator panel 2 Using a small straight blade screwdriver turn the base of the bulb 1 4 turn counterclockwise 3 Using a needle nose plier or similar tool pull the lamp out of the indicator panel hous...

Page 128: ...use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled 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 Re...

Page 129: ... several times using the electric start 8 Dry the spark plug and reinstall or replace it with a new plug 9 Tighten the carburetor drain screw 1 or reinstall the bowl drain 2 10 For two cycle engines reinstall the crankcase drain screw 11 Turn the fuel valve on 12 Attempt to start the engine If necessary repeat the drying procedure 13 Take the ATV to your dealer for service as soon as possible whet...

Page 130: ...park arrestor while the system is hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas Never go under the vehicle while it s incline...

Page 131: ...the muffler back the vehicle onto an incline so the rear of the vehicle is one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 3 and 4 6 If particles are still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than the rear Set the parking brake and block the wh...

Page 132: ...ind the heat shield for it to seal properly The drain screw is located at the bottom of the recoil housing Use a wrench to remove the screw Be sure to reinstall the screw after draining the housing NOTE Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines some engine oil will be lost if crankcase drain is opened Drain Locations Illustration 1 250 and 400 Engines ...

Page 133: ...RPM However in high range at 3 MPH the engine would be running at only 1500 RPM Whenever operating this close to the engagement speed the engine may be running at a speed too low to provide the pinch needed to prevent belt slip Belt slip is responsible for creating the excessive heat that destroys belts and causes outer clutch covers to fail By switching to low range while operating at low ground ...

Page 134: ...NG Failure to comply with the instructions in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates a...

Page 135: ...olution or tap water into the battery 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 of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention ...

Page 136: ...vent tube from the battery 3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the ATV Be careful not to tip a conventional battery sideways which could spill electrolyte 1 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disc...

Page 137: ...tery and result in a shorter life It can also hinder vehicle performance Battery Storage When the vehicle is placed in storage for three months or more the battery should be removed stored out of the sun in a cool dry place and tested monthly Before reusing take the battery to your dealer for testing and recharging Power plug leads may need to be bent down so that the battery cover can be installe...

Page 138: ...efore and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger 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 volt...

Page 139: ...ning and safety labels are damaged contact your a Polaris dealer for free replacement Polaris does not recommend the use of a high pressure type car wash system for washing the ATV If a high pressure system is used exercise extreme care to avoid water damage to the wheel bearings transmission seals body panels brakes and warning labels NOTE Grease all zerk fittings immediately after washing and al...

Page 140: ...n for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve off and drain the carburetor bowl Oil and Filter 4 Cycle Warm the engine and change the oil and filter Air Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box and drain the sediment tube Breather Filter s On 4 cycle engines inspect and clean or replace the breat...

Page 141: ...rocedure 1 Support the front end of the machine so the engine is level or tilted slightly rearward 2 Remove the spark plug s Rotate the piston to BDC and pour approximately two ounces of Polaris recommended oil into the cylinder NOTE Be sure to use 2 cycle oil in 2 cycle engines and 4 cycle oil in 4 cycle engines 3 Apply dielectric grease to the inside of the spark plug cap and install the cap ont...

Page 142: ... can be left connected during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Engine Anti Freeze Test engine coolant strength and change if necessary Coolant should be replaced every two years Storage Area Covers Set the tire pressure and safely support the ATV with the tires 1 2 off the ground Be sure the storage area is well ventilat...

Page 143: ... 8 oz 2871654 Premium Drive Hub Fluid 8 oz 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 Nyogelt Coolant 2871323 60 40 Coolant gal 2871534 60...

Page 144: ... for efficient enga gement Towing pushing at low RPM low ground speed Use low range only Utility use plowing snow dirt etc Use low range only Stuck in mud or snow 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 large ob jects from a stopped posi tion S...

Page 145: ...t in fuel Drain the fuel 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 plu...

Page 146: ...se ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel 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 Polaris dealer Electronic throttle control malfunction See y...

Page 147: ...es 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 to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction...

Page 148: ... 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 THE PURCHASER MUST COMPLETE AN ATV SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE ATV No verification of registration will be sent to the purchaser as the copy of the Warranty Registrat...

Page 149: ...rrosion 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 replacement of any defective materials or components or products THE ...

Page 150: ...anty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY 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 personn...

Page 151: ...ely 63 73 Driving Through Water 70 Driving Uphill 66 E Electrical Switches 37 Engaging Wheel Hubs 48 Engine Cooling System 99 101 Engine Fogging 139 Engine Oil Check 98 Equipment Modifications 11 F FEATURES 48 55 Filter Systems 118 119 Front Brake 104 Front Gearcase Oil Change 95 Front Gearcase Oil Check 95 Front Wheel Hub Tightening 114 Fuel Filter 43 Fuel Safety 44 Fuel Stabilizer 138 Fuel Tank ...

Page 152: ... Sidehilling 67 Spark Arrestor 74 128 129 Spark Plug Removal and Replacement 126 Spark Plugs 126 Starting a Cold Engine 59 S Starting a Warm Engine 60 Starting the Engine 59 60 Steering Assembly 107 Stop Switch 37 Storage Tips 138 140 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 125 Throttle Cable Freeplay 110 Throttle Lever 38 Tire Tread Depth 114 Toe Alignment 106 Towing Capacitie...

Page 153: ...HE USA WARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS Avoid paved surfaces which may adversely affect handling and control Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns Wear eye protection helmet and protective apparel READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS NEVER ALWAYS USE AN APPROVED HELMET AND PROTECTI...

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Polaris 600 Dragon SP, Owner'S Manual

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Summary of Contents for 600 Dragon SP

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