Polaris ATV 2002 Page 152 Owner'S Manual Download

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149

MAINTENANCE AND LUBRICATION

Lights -- Adjustment -- Replacement

Headlight Lamp Replacement (Gen IV)

1. Using a small flat blade screwdriver, push in on the lock tab

through the two small openings at the front of the headlight pod.

2. Lift the pod lightly while depressing the tabs.
3. Remove the screw in the back of the headlight pod

4. Lift pod cover up. Disconnect speedometer harnesses from

speedometer. Unplug indicator light harness and remove pod

cover.

5. Unplug headlamp from wiring harness.
6. Remove boot and locking collar from back of lamp housing.

7. Grasp base of lamp and lift it out.
8. Reverse previous steps to replace lamp and reassemble pod. Make

sure tab on lamp locates properly in housing.

Snap pins

into tabs

Position

knob in

slot and

secure in

locking

tabs

Slip O-Ring

over pin

Adjustment

Knob Stop

Route indicator

harness over

handlebar

Summary of Contents for ATV 2002

Page 1: ......

Page 2: ...own to cause cancer birth de fects or other reproductive harm A card containing important safey information should be attached to the owner s manual on the next page If you cannot locate this card or...

Page 3: ...Indicates a potential hazard that could result in serious injury or death WARNING...

Page 4: ...ted 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 polarisindustrie...

Page 5: ...for safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance Major repairs are covered in the Polaris Service Manual and should be performed by a Fa...

Page 6: ...FETY TRAINING When you purchased this vehicle your dealer offered a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed material which...

Page 7: ...Issues 8 Decals and Locations 12 Operator Safety 22 Features and Controls 43 65 Controls 43 Features 58 Operation 66 70 Pre Ride Inspection 66 Vehicle Break In Period 67 Starting the Engine 70 Carryi...

Page 8: ...commendations 94 Maintenance Record 100 Cooling System 101 Lubrication 104 Filter Systems 127 Adjustments 130 Lights 146 Spark Plugs 153 Water Service 154 Spark Arrestor 155 Recoil Housing 157 PVT 158...

Page 9: ...in a safe place Your key can be duplicated only by obtaining a key blank from Polaris and having it cut by mating it with your existing key The vehicle frame and engine serial numbers are important f...

Page 10: ...manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury Indicates a potential hazard that could result in serious injury or death Indicates a p...

Page 11: ...available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be rep...

Page 12: ...lso wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating this ATV S Never operate at excessive...

Page 13: ...this manual on level ground Avoid crossing the side of a steep hill if possible S Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady s...

Page 14: ...c Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any other mod...

Page 15: ...your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing r...

Page 16: ...13 SAFETY Safety Decals and Locations 1 7079083 E1997 2000 IF OWNER S MANUAL IS MISSING CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT WARNING...

Page 17: ...14 SAFETY Safety Decals and Locations 2 3...

Page 18: ...prevent flipover avoid sudden braking or sharp turns F Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle F PARKING BRAKE...

Page 19: ...16 SAFETY Safety Decals and Locations 4 5 6...

Page 20: ...S Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered...

Page 21: ...lt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not modify engine or clutch Doing so can cause part failure possible imbalance and excessive engine RPM which can...

Page 22: ...ecals and Locations 9 9 DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 lbs Rear 180 Lbs...

Page 23: ...verse override is controlled by the override switch See your Owner s Manual OVERRIDE SWITCH 7079906 AWD Models 2WD Models 7077542 TRAILER MAX WEIGHT 1225 LBS 556 KG ON LEVEL GROUND 850 LBS 368 KG UP T...

Page 24: ...tional Standards Institute 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 helmet face shield offer...

Page 25: ...rse and the 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 Fail...

Page 26: ...rol this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed d...

Page 27: ...AN HAPPEN The ATV tires are designed for off road use Paved surfaces may seriously affect handling and control of the ATV and may cause the vehicle to go out of control HOW TO AVOID THE HAZARD Avoid o...

Page 28: ...eets roads or highways WHAT CAN HAPPEN You can collide with another vehicle HOW TO AVOID THE HAZARD Never operate this ATV on any public street road or highway even a dirt or gravel one In many states...

Page 29: ...r chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accid...

Page 30: ...Could result in an accident HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while driving this ATV POTENTIAL HAZARD Operating this ATV at excessive speeds WHAT CAN HAPPEN Increases y...

Page 31: ...NTIAL HAZARD Attempting wheelies jumps and other stunts WHAT CAN HAPPEN Increases the chance of an accident including an overturn HOW TO AVOID THE HAZARD Never attempt stunts such as wheelies or jumps...

Page 32: ...ures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce you...

Page 33: ...T CAN HAPPEN You can come upon hidden rocks bumps or holes without enough time to react Could result in the ATV overturning or going out of control HOW TO AVOID THE HAZARD Go slowly and be extra caref...

Page 34: ...Could cause loss of traction or vehicle control which could result in an accident including an overturn HOW TO AVOID THE HAZARD Do not operate on excessively rough slippery or loose terrain until you...

Page 35: ...t low speeds before attempting to turn at faster speeds Do not turn at excessive speed POTENTIAL HAZARD Operating on excessively steep hills WHAT CAN HAPPEN The vehicle can overturn more easily on ext...

Page 36: ...ribed in the Owner s Manual See pages 80 through 83 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forw...

Page 37: ...oing down hills as described in the Owner s Manual See page 82 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Sh...

Page 38: ...any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 83 Be very careful when turning on any hill Avoid crossing the side of a steep hill i...

Page 39: ...hill Apply the brakes Lock parking brake after you are stopped If you begin rolling backwards Keep weight uphill never apply engine power Never apply the rear brake while rolling backwards Apply the s...

Page 40: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Page 41: ...voiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability...

Page 42: ...as described in the Owner s Manual Supplement POTENTIAL HAZARD Operating this ATV with improper modifications WHAT CAN HAPPEN Improper installation of accessories or modification of this vehicle may...

Page 43: ...ling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See pages 72 through 74 POTENTIAL HAZARD Riding on frozen...

Page 44: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Page 45: ...r physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death WARNING WARNING Leaving the keys in the ignition c...

Page 46: ...ine Stop Switch 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 stuck throttle or other...

Page 47: ...s will cease when the operator releases the throttle lever Choke Refer to the engine starting procedure on page 70 for correct choke and throttle settings during starting Do not start or operate an AT...

Page 48: ...t brake lever travel and reservoir 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...

Page 49: ...straight If the fluid level is low add DOT 3 PN 2870990 only The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not...

Page 50: ...Important Safeguards S The parking brake may relax when left on for a long period of time This could cause an accident S Do not leave the vehicle on a hill depending on the parking brake for more tha...

Page 51: ...ressure to brake the rear wheels without skidding Aggressively applying the rear brake when backing down a hill may cause rear tip over Brake Fluid Level It will be necessary to check the brake fluid...

Page 52: ...F For vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on reserve...

Page 53: ...ed or where gasoline is stored S Do not over fill the tank Do not fill the tank neck S If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing S Ne...

Page 54: ...hine Refer to your Owner s Manual Supplement to determine the type of engine your vehicle has The tank capacity is 2 quarts 1 9 l On models with a two cycle engine use only Polaris injection oil Never...

Page 55: ...nual Supplement for specification NOTE To extend belt life use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of tim...

Page 56: ...f in Reverse to find neutral Refer to the gear shift pedal illustrated on this page Once the vehicle is in neutral start the engine by engaging the starter Brake Start This model also has a brake star...

Page 57: ...up follow this procedure 1 With the transmission in neutral hold the brake lever 2 With the throttle closed raise the gear shift pedal one full stroke to shift into first gear 3 Release the brake leve...

Page 58: ...required for vehicle movement S Avoid turning at sharp angles in reverse S Avoid backing on steep inclines Light Switches and Indicator Lights Be careful when operating in reverse Make certain your pa...

Page 59: ...brakes smoothly and evenly As you slow down shift to a lower gear Be certain the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires...

Page 60: ...inning fast enough to start and restores compression for starting 1 Be certain your vehicle is on a level surface and the parking brake is set See page 74 2 Take the machine out of gear 3 Grasp the re...

Page 61: ...wheels regain traction the front wheels will automatically disengage NOTE The override switch also allows activation of Demand 4 Drive AWD in reverse if Demand 4 Drive switch is on There is no limit t...

Page 62: ...wheel hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted NOTE If the hubs remain engaged after following these instructions ret...

Page 63: ...ion 1 Transmission Neutral Green 2 Transmission Reverse Yellow 3 Oil Warning Red On 2 cycle models this light indicates a low oil level 4 High Temp Red Will light only if engine overheats 5 All Wheel...

Page 64: ...rip Miles 000 0 M Hours 00000 0 H To reset Trip Miles 1 Toggle to Trip Miles 2 Hold down button approximately 4 seconds The speedometer also has additional features accessed through a sub menu These f...

Page 65: ...once to scroll through the four available functions Each function will be displayed as follows Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE Changing Di...

Page 66: ...the 50 hour service setting example from above the speedometer will take the 50 hour setting and add it to the value of the hour meter This will be the value displayed when the operator checks when se...

Page 67: ...y The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval When this is done the display will return to the normal menu showing odomete...

Page 68: ...ccessories such as hand held spot lights On select models an outlet is located on the front headlight pod To determine if your vehicle is equipped with auxiliary power outlet please check your Owner s...

Page 69: ...unction 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element...

Page 70: ...lined on page 49 2 Fill the oil tank with Polaris injection oil 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling...

Page 71: ...r the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see your...

Page 72: ...t an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fl...

Page 73: ...and can be adjusted gradually depending on how much choke is needed for starting 7 Do not press the throttle while starting the engine 8 Activate the starter for a maximum of five seconds releasing th...

Page 74: ...reduce moisture accumulation in the oil tank when the ATV is operated in freezing temperatures If you use your ATV all year round it is important to check your oil level frequently A rising oil level...

Page 75: ...weight 30 lbs 14 kg Select models may tow up to 1225 556 kg on level ground only with a maximum vertical hitch weight of 35 lbs 16 kg Refer to your Owner s Manual Supplement to determine your machine...

Page 76: ...ack only increases the possibility of vehicle tip over S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations w...

Page 77: ...rely fasten load and operate with ex tra caution Always attach the tow load to the hitch point designated for your ATV S EXTREME CAUTION MUST BE USED when operating with loads extending over the rack...

Page 78: ...val 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 induct...

Page 79: ...nction 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element...

Page 80: ...r 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 amoun...

Page 81: ...e wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the ou...

Page 82: ...e skid and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engagedcan assistin controlling the vehicle in slippery areas 5 Never apply brakes during a skid Complete los...

Page 83: ...steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV Indicates a potential hazard that could result in serio...

Page 84: ...he hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn...

Page 85: ...ar of the vehicle 3 Slow down 4 Apply the brakes slightly to aid in slowing Familiarize yourself with the auxiliary rear brake pedal and its use in the event loss of normal service brakes occurs Do no...

Page 86: ...turn handlebars full left while facing front of ATV 5 While holding service brake release parking brake lock and slowly allow ATV to roll around to your right until ATV is pointing across the hill or...

Page 87: ...d water which exceeds the recommended maxi mum depth go slowly balance your weight carefully avoid sud den movements maintain a slow and steady forward motion Do not make sudden turns or stops and do...

Page 88: ...you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches Not all obstacles are visible Travel with caution on trails se...

Page 89: ...of control may result NOTE Most Polaris ATVs are equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at...

Page 90: ...ace the transmission in gear or in park 3 Set the parking brake 4 Avoid parking on an incline If it is necessary to park on an incline always block the rear wheels on the down hill side as shown above...

Page 91: ...an lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Service and adjustments...

Page 92: ...on Pre ride Pre ride Replace engine 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 operati...

Page 93: ...Counterbal ance 400 Engines 20 hrs Monthly Check oil level change annually L Engine breather filter 4 cycle 20 hrs Monthly Inspect replace annually and as needed J Brake pad wear 10 hrs Monthly Inspe...

Page 94: ...Enricher Cable 50 hrs 6 months Inspect adjust lubricate replace if necessary Coolant strength pressure test system 100 hrs 6 months Inspect strength seasonal ly pressure test system annually Front hu...

Page 95: ...J L Ignition Timing 100 hrs 12 months Inspect and adjust as needed J L Fuel System 100 hours 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor Re place lines every two...

Page 96: ...x 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 bearings 2wd 300 hrs 36 months Inspect replace if neces sary L Idle Spee...

Page 97: ...t 100 hours 5 Front Gearcase Oil GL5 80 90 Weight Gear Lube See Page 122 Models with Visco drive require special lubricant See your owner s manual sup plement for requirement Change annually or at 100...

Page 98: ...MAINTENANCE AND LUBRICATION Lubrication Recommendations Operating Range Full 4 Transmission dipstick 6 Front Prop Shaft U Joint Fill plug 5 Front Gear Case 4 Transmission plug 7 Propshaft Yoke Fill pl...

Page 99: ...ith grease gun Every 3 months or 50 hours 12 Front A Arm Pivot Shaft L Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 13 Counter Balance Housing 400 SAE 10...

Page 100: ...BRICATION Lubrication Recommendations 10 Axle Cardan Front Drive AWD Models 13 Counterbalance Dipstick 14 Steering Post Bushing 11 Ball Joint 12 Front A Arm Pivot Shaft Upper 9 4 O clock position 9 De...

Page 101: ...r L Grease Locate fitting and grease Semi annually 20 Rear Anti Roll Bar L Grease Locate fitting and grease Semi annually L More often under severe use such as wet or dusty conditions Polaris Premium...

Page 102: ...CATION Lubrication Recommendations 16 Swing Arm Bushings 15 Rear Axle Bearing 17 Upper Control Arm 19 Rear Wheel Hub Bearing Carrier 20 Rear Anti Roll Bar 18 Lower Control Arm INDEPENDENT REAR SUSPENS...

Page 103: ...UBRICATION Periodic Maintenance Record Use the following chart to record periodic maintenance work Maintenance Interval Performed Servicing Date Servicing Dealer or Person Remarks First 5 Hrs 25 Hrs 5...

Page 104: ...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 itse...

Page 105: ...I A To access the pressure cap clean the area around the oil cap and remove the oil cap 2 cycle models Remove front cover by placing your fingers under the front of the cover and pulling upward Reinst...

Page 106: ...and a fresh mixture of antifreeze and water be added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant...

Page 107: ...ubrication demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are the best available in the m...

Page 108: ...ient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output lower fuel consumption and easier starting in cold temperatures Although...

Page 109: ...upplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Lift boot 1 up off adjuster...

Page 110: ...s to open See Owner s Manual Supplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise...

Page 111: ...e jam nut You will need to bottom the cable to the carburetor slidevalve cap Adjust at throttle cable adjuster near the throttle block See page 137 for adjustment procedure Oil and Filter Change The r...

Page 112: ...lug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 17 ft lbs 1 93 2 35 kg m 8 Disconnect the...

Page 113: ...plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 14 Reinstall drain plug 15 Remove dipstick an...

Page 114: ...drain completely 6 Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to...

Page 115: ...and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the l...

Page 116: ...aling surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Place shop towels beneath oil filter Using an o...

Page 117: ...or one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used f...

Page 118: ...lace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Pl...

Page 119: ...g brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the up...

Page 120: ...miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug 1 and check the lubricant level Use the illustration and the chart belo...

Page 121: ...g 3 Remove transmission drain plug located on the bottom left hand side and drain the oil refer to page 117 for the location of the Magnum drain plug Catch and discard used oil properly 4 Clean and re...

Page 122: ...is located near the rear brake disc The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a...

Page 123: ...lt B in to allow the removal of drain plug C 5 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 6 After the oil has drained completely install a new sealing...

Page 124: ...ug dipstick 2 Remove transmission drain plug side and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug 4 Add 32 oz 948 ml Polaris Premium Synthetic Gearcase Lubri...

Page 125: ...ant to use is GL5 80 90 Weight Gear Lube Type B The lubricant level in this type of gearcase cannot be checked You must periodically drain it and refill it according to the following procedure Gearcas...

Page 126: ...eads The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a ne...

Page 127: ...uld be added or changed as necessary The oil should be changed annually especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the o...

Page 128: ...the dipstick If overfilled excess oil will be expelled through the vent hose 4 Reinstall dipstick NOTE Recommended Oil Level 2 Counter Balance Oil Changing Procedure 1 Remove skid plate 2 Remove count...

Page 129: ...0 30 seconds 3 Stop the engine remove dipstick and wipe dry with a clean cloth 4 Screw in the dipstick completely remove it and read the oil level NOTE The dipstick must be screwed in to keep the angl...

Page 130: ...r 5 Wash pre filter in soapy water rinse and let dry 6 Re install pre filter over main filter Replace main filter if required Filter Installation Procedure 1 Check condition of airbox and replace if n...

Page 131: ...ure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside NOTE Replace the air filter every 50 hours and possibly more often in very dirty con...

Page 132: ...ine 2 Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed 3 Check hoses for cracks deterioration abrasion or leaks Replace as needed 4...

Page 133: ...e Alignment You can check the toe alignment of the vehicle using the following method The recommended toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer...

Page 134: ...s side surface of the rear tires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of front rim Rear rim measurement should be 1...

Page 135: ...djustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through your Polaris...

Page 136: ...t Be sure handlebars do not hit gas tank or any other part of machine when turned fully to left or right 4 Torque handlebar adjuster block bolts to 10 to 12 ft lbs NOTE Tighten bolts so there is an eq...

Page 137: ...ated and the diaphragm should be replaced Always fill the reservoir as indicated whenev er the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid S Check b...

Page 138: ...orn to 3 64 1 cm which is about the thickness of a dime S Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to...

Page 139: ...carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM The following variations to ai...

Page 140: ...w A in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Free Play Adjustment Throttle cab...

Page 141: ...AND LUBRICATION Adjustments Cylinder Head Cylinder Base Fastener Torque 2 Cycle Models Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service o...

Page 142: ...e handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placi...

Page 143: ...2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found on page 140 The following items should be checked occa...

Page 144: ...itical component operations Service work must be performed by your authorized Polaris dealer Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always r...

Page 145: ...r Always inspect the drive chain prior to operating the vehicle checking for damaged or missing O rings rollers and correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8...

Page 146: ...rd to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection 1 If the chain needs adjustment use the following procedure Never adjust or opera...

Page 147: ...hout the hitch and 45 ft lbs 13 7 kg m for machines with a hitch 7 Tighten caliper mount bolts 10 12 ft lbs 1 4 1 7 kg m 8 Remove pin punch 9 Roll ATV foward checking chain tension in several places a...

Page 148: ...etting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss during high altitude operation Contact your dealer 3 On 2 cycle...

Page 149: ...g and rotate clockwise firmly NOTE Bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector Keep your headlights and taillights clean Poor lighting while ridi...

Page 150: ...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 headlight aim The most intense part of the headlight beam should be...

Page 151: ...l surface with the headlight approximately 25 7 6 m from a 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 a...

Page 152: ...pod 4 Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 5 Unplug headlamp from wiring harness 6 Remove boot and locking collar fr...

Page 153: ...with the headlight approximately 25 7 6 m from a 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 t...

Page 154: ...pod 5 Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 6 Unplug headlamp from wiring harness 7 Remove O Ring from headlight pivo...

Page 155: ...moved in step 1 Indicator Lamp Replacement Style I 1 Remove the upper headlight pod Gen 4 or the front cover Gen 2 to access the back of the indicator panel 2 Using a small straight blade screwdriver...

Page 156: ...used by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nos...

Page 157: ...electric start S Dry the spark plug and reinstall or re place with a new plug S Tighten the carburetor drain screw 1 or reinstall carburetor drain 2 S Reinstall crankcase drain S Turn the fuel valve t...

Page 158: ...hen cleaning the spark arrestor you must follow the safeguards listed below to avoid serious injury or death S Do not perform this operation immediately after the engine has been run because the exhau...

Page 159: ...in neutral and repeat steps 2 and 3 5 If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the park...

Page 160: ...ravelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines...

Page 161: ...Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe S Do not m...

Page 162: ...clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch...

Page 163: ...lists provide a guideline for when to use low range rather than high Low Range S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain swamps mountains etc at low g...

Page 164: ...situation could result causing serious injury or death WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote Exte...

Page 165: ...e of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with cle...

Page 166: ...hold down strap 6 Verify that cables are properly routed NOTE S When your ATV is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool d...

Page 167: ...pull the panel forward and outward to disengage the two rear tabs 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top r...

Page 168: ...ngs immediately after washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your ATV is with a garden hose and a pai...

Page 169: ...for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve to OFF and drain the carburetor bowl completely Oil And Filter Change 4 Strokes Warm the engine and chang...

Page 170: ...Chain Lube to the drive chain s Battery Maintenance Remove the battery and add distilled water as required to the proper level Do not use tap water which may contain minerals that reduce battery life...

Page 171: ...the fuel system with Polaris Carbon Clean 5 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline to eliminate any fuel remaining in...

Page 172: ...of Low Range is high ly recommended for cooler PVT oper ating temperatures and longer compo nent life Insufficient warm up of ATVs exposed to low ambi ent temperatures Warm engine at least 5 min then...

Page 173: ...e peat several times as required During this procedure the throttle should not be held at the full posi tion for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking oc...

Page 174: ...uses for questions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plug...

Page 175: ...veruse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Control Malfunct...

Page 176: ...the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for wa...

Page 177: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels tha...

Page 178: ...ce you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selli...

Page 179: ...Fuel Stabilizer 166 Fuel System 49 51 Fuel Valve 49 Gearcase Oil Changing Procedure 122 Handlebar Adjustment 133 Headlight Adjustment 147 150 Headlight Lamp Replacement 146 149 Indicator Lamp Replace...

Page 180: ...tion 117 119 Transmission Oil Changing Procedure 118 121 Transporting 168 Traveling Downhill 82 Traveling Uphill 80 Troubleshooting 169 172 Turning Around On a Hill 83 Understanding Warnings 7 Vehicle...

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Summary of Contents for ATV 2002

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Polaris ATV 2002, Owner'S Manual

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Summary of Contents for ATV 2002

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