Polaris OUTLAW 110 2017 Page 151 Owner'S Manual For Maintenance And Safety Download | Manualshive

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149

Maintenance

Cleaning

Washing the ATV

If a high pressure water system is used for cleaning (not recommended), exercise extreme
caution. The water may damage components and could remove paint and decals. Avoid
directing the water stream at the following items:
• Wheel bearings
• Radiator
• Transmission seals

• Brakes
• Cab and body panels
• Labels and decals

If warning and safety labels are damaged, contact your POLARIS dealer for free
replacement.
Grease all zerk fittings immediately after washing. Allow the engine to run for a while to
evaporate any water that may have entered the engine or exhaust system.

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Summary of Contents for OUTLAW 110 2017

Page 1: ...ual carefully It contains important safety information Adult supervision is required at all times Operation is prohibited for anyone under age 10 OUTLAW 110 SPORTSMAN 110 Owner s Manual for Maintenanc...

Page 2: ...it has been removed please call 1 800 342 3764 for assistance WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other r...

Page 3: ...1 Visit us at www polaris com...

Page 4: ...een the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions...

Page 5: ...manual Never allow a child under the age of 16 to operate an ATV without adult supervision Children differ in skills physical abilities and judgement Some children may not be able to operate an ATV s...

Page 6: ...ed to read and understand the information in your owner s manual You must also take an ATV training course before you begin riding Ask your parents to explain anything you don t understand and pay clo...

Page 7: ...our ATV 40 Pre Ride Check 47 Riding Rules 50 Adult Section 55 Vehicle ID Numbers 56 Features and Controls 57 Operation 67 Emission Control Systems 94 Maintenance 96 Specifications 158 POLARIS Products...

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

Page 9: ...dures before operating a POLARIS ATV Keep this manual with the ATV Never operate an ATV without proper instruction Take a training course For your child s safety be sure your child can reach and opera...

Page 10: ...erCoursesm that is available to you and your eligible family members This training is included in the purchase price of your ATV In addition you were provided with printed material and a video or DVD...

Page 11: ...isit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training FOR MORE INFORMATION...

Page 12: ...eeds established safety standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE...

Page 13: ...al Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Gloves Off road style gloves with knuckle pads are the best for comfort and prot...

Page 14: ...decrease stability or change performance may present a greater risk to inexperienced or younger operators and could result in loss of control and serious injury or death Use only POLARIS approved acce...

Page 15: ...gs are provided for your child s safety Be sure to explain to your young driver that the hazards outlined in this section of the owner s manual MUST be avoided at all times See the RIDING RULES sectio...

Page 16: ...uations and on different types of terrain Beginning and inexperienced operators should complete an ATV training course They should then regularly practice the skills learned in the course and the oper...

Page 17: ...re refueling is performed or where gasoline is stored Do not overfill the tank Do not fill the tank neck If gasoline spills on your skin or clothing immediately wash it off with soap and water and cha...

Page 18: ...ntenance procedures and schedules described in the owner s manual Protective Apparel Operating this ATV without wearing an approved helmet increases the risk of a serious head injury in the event of a...

Page 19: ...and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect op...

Page 20: ...void operating the ATV on pavement ATV tires are designed for off road use If it s unavoidable travel slowly and avoid sudden turns or stops Operating on Public Roads Operating this ATV on public stre...

Page 21: ...ditions and your experience Physical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce your ability to control the vehicle or cause loss of...

Page 22: ...for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stu...

Page 23: ...n Always follow proper procedures for climbing hills as described in the owner s manual See page 82 Operating on Steep Hills Operating on excessively steep hills could cause an overturn Never operate...

Page 24: ...scribed in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 85 Always check the terrain carefully before descending a hill Shift your weight rearw...

Page 25: ...urn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 84 Never attempt t...

Page 26: ...radually right lever When fully stopped apply the rear brake as well left lever and then lock the parking brake If the ATV begins rolling downhill Keep weight uphill Never apply engine power Never app...

Page 27: ...y rough slippery or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessively rough slippery or loose terrain until you ve learned and practiced the...

Page 28: ...tenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident Always use the size and type of tires specified for your ATV Always main...

Page 29: ...ed and used according to approved instructions Your POLARIS dealer can assist Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn Before operating in a...

Page 30: ...If it s unavoidable to enter water that exceeds the height of the footrests Travel slowly Balance your weight carefully Avoid sudden movements Maintain a slow and steady forward motion Do not make sud...

Page 31: ...ndling which could cause loss of control or an accident Never haul cargo or tow a load with this ATV Never tow or pull an object behind the ATV A wagon sled or other towed object does not have brakes...

Page 32: ...ult in an accident or overturn Always remove the ignition key when the vehicle is not in use Physical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Per...

Page 33: ...ndition The environment was controlled as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including Instrument and calibration uncertai...

Page 34: ...ions of the labels on the vehicle If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by PO...

Page 35: ...per training or instruction at speeds too fast for your skills or the conditions on public roads a collision can occur with another vehicle with a passenger passengers affect balance and steering and...

Page 36: ...his ATV on HILLS steeper than 15 degrees 15 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill REVERSE operation can be dangerous even at low speeds Steerin...

Page 37: ...jury or death Cold tire pressure Front 3 0 psi 20 7 kPa Rear 3 0 psi 20 7 kPa Maximum Weight Capacity 180 lbs 81 7 kg Tire Pressure Warning SPORTSMAN WARNING Improper tire pressure or overloading can...

Page 38: ...36 Safety Safety Labels and Locations No Passenger Warning WARNING NEVER ride as a passenger Passengers can cause a loss of control resulting in SEVERE INJURY or DEATH...

Page 39: ...7 Safety Safety Labels and Locations SPORTSMAN Rack Warning WARNING DO NOT TOW Vehicle damage or tipover may result causing severe injury or death Maximum Rack Loads Front 15 lbs 7 kg Rear 30 lbs 14 k...

Page 40: ...rd under belt clutch guard To prevent serious injury do not operate vehicle with guard removed Do not touch clutch cover cover may become hot Do not modify engine or clutch Doing so can cause part fai...

Page 41: ...39 Youth Section...

Page 42: ...ifications section beginning on page 158 for your ATV s capacity CHILDREN Before you ride your new POLARIS ATV there are some important things that you need to know Your safety and the safety of other...

Page 43: ...to shut the engine off quickly The button must be up before you can start the engine again 2 Horn Button Press the horn button to sound the horn 3 Throttle Control Press the throttle lever with your t...

Page 44: ...42 Know Your ATV 4 Shift Lever The shift lever is on the right side of the ATV Read about how to use the shift lever on page 62 4 Shift Lever...

Page 45: ...have an adult put gas in your ATV Never try to do it yourself 6 Seat Latch The seat latch is under the left edge of the seat Reach under the left rear fender and pull back on the latch to remove the...

Page 46: ...front brake Always squeeze both brake levers at the same time Always squeeze both brake levers at the same time or you could lose control of the ATV and be seriously injured Always take your thumb off...

Page 47: ...ed snugly to your right wrist and to your ATV every time you drive If you fall off your ATV the tether strap will pull away from the switch and the engine will stop Never ride without the tether strap...

Page 48: ...46 Know Your ATV Let s review the three ways to stop the engine of your ATV 1 Push the engine stop switch down 2 Pull the tether strap off the ATV 3 Turn the key off...

Page 49: ...t stick Check this by pushing the throttle lever toward the handlebar and then letting go The lever should come right back to where it was before you pushed it If it comes back slowly or stays close t...

Page 50: ...e your ATV safely Never start the engine if your ATV has sticky brakes You could be seriously hurt if you ride with sticky brakes Have an adult or your POLARIS dealer fix the sticky brakes before you...

Page 51: ...check the oil on their own An adult should always be in charge of keeping the gas and oil levels at the full marks 6 This last check is done with the engine running You must check to make sure that al...

Page 52: ...driving an ATV Adults have riding rules too The rules help keep us safe when we ride The adult with you is your teacher Always pay attention to what your teacher says so you can learn how to always dr...

Page 53: ...r hands from sun and wind Gloves will also protect your hands from scrapes and scratches Boots Wear sturdy over the ankle boots to keep your feet dry Boots will also protect your feet and ankles from...

Page 54: ...the ATV harder to drive You may lose control and hurt yourself and your passenger Always drive your ATV while sitting down Keep both hands on the handlebars and keep both feet on the footrests Always...

Page 55: ...night Your ATV doesn t have lights that are safe for driving in the dark Learn where there are lakes rivers ponds and ditches in your driving area Stay away from them Never ride on frozen water You co...

Page 56: ...54 Respect your ATV respect your environment and you will earn the respect of everyone Enjoy riding your new POLARIS ATV...

Page 57: ...55 Adult Section...

Page 58: ...ith one of your existing keys The ignition switch must be replaced if all keys are lost Vehicle Model Number ____________________________________________________________________ Frame VIN ____________...

Page 59: ...the key clockwise to the ON position before starting the engine To avoid draining the battery always turn the key to the OFF position when the engine is not running Always remove the ignition key whe...

Page 60: ...F position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency Both the main switch and the engine stop switch shut off all electr...

Page 61: ...rols Horn Button Use the horn for emergencies and to let others know you re near Engine Start Button The start button is located on the left handlebar control Follow the Starting the Engine procedure...

Page 62: ...result in an accident if the throttle lever sticks during operation Always check the lever for free movement and return before starting the engine Also check occasionally during operation The throttle...

Page 63: ...rottle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever engine spe...

Page 64: ...g shift linkage adjustment is important to assure proper transmission function See your dealer or other qualified person if you experience any shifting problems Shift Pattern F Forward Gear N Neutral...

Page 65: ...the same time to apply the brakes The left lever controls the rear brakes The right lever controls the front brakes WARNING Applying only one brake could cause loss of control and result in serious i...

Page 66: ...eze and release the brake lever The parking brake will release automatically 5 Always lock the parking brake whenever the vehicle is left unattended WARNING Operating the ATV while the parking brake i...

Page 67: ...ights Indicator Description Neutral Transmission is in neutral Reverse Transmission is in reverse Low Fuel The ATV can operate 7 10 miles 11 16 km before the tank is completely empty Check Engine A fl...

Page 68: ...ow the handlebars Use unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Non ethanol fuel is recommended Do not use fuel with ethanol content greater than 10 percent such as E 85 f...

Page 69: ...oline No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine will result in more efficient performance and longer life for th...

Page 70: ...asoline See page 15 2 Check the oil level See page 107 Add the recommended oil as needed to maintain the oil level in the safe operating range 3 Drive slowly at first Select an open area that allows r...

Page 71: ...maintenance at 10 hours or one month Item At 10 Hours or One Month End of Break In Period See Page Engine oil change Perform break in oil change 108 Oil pre filter screen Clean filter with oil change...

Page 72: ...Ride Checklist Item Remarks Page Brake system lever travel Ensure proper operation 123 127 Front suspension Inspect lubricate if necessary 104 Rear suspension Inspect lubricate if necessary 104 Steer...

Page 73: ...Check for proper operation 143 Brakelight Check for proper operation 141 Air filter pre filter Inspect clean or replace 134 Drive chain Check condition and slack refer to drive chain adjustment 131 F...

Page 74: ...the engine or let it run in an enclosed area 5 Operate this vehicle off road only Never operate the vehicle on pavement or on any public street road or highway including dirt and gravel roads 6 Never...

Page 75: ...fore or while operating an ATV 9 Always use the size and type of tires specified for your vehicle Always maintain proper tire pressure 10 Never operate a damaged ATV After any overturn or accident hav...

Page 76: ...ing could cause engine damage Allow the engine to warm up for several minutes before operating 1 Shift the transmission to neutral 2 Lock the parking brake 3 Sit on the vehicle Attach the tether strap...

Page 77: ...brake lever must be engaged or the engine won t start 7 Do not press the throttle while starting the engine Activate the starter for a maximum of five seconds releasing the button when the engine star...

Page 78: ...oving 3 Shift the transmission to neutral 4 Stop the engine There are three ways to stop the engine Turn the key off Push the engine stop switch down Pull the tether strap off the ATV 5 Lock the parki...

Page 79: ...ngine and allow it to warm up 4 Check your surroundings and determine your path of travel 5 Squeeze the left brake lever 6 Shift the transmission to the desired gear 7 Slowly release the brake lever 8...

Page 80: ...side 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 outer footrest This technique alt...

Page 81: ...ecautions when operating in reverse 1 Always check for obstacles or people behind the vehicle 2 Always avoid backing downhill 3 Back slowly 4 Apply the brakes lightly for stopping 5 Avoid turning at s...

Page 82: ...rfaces Whenever riding on slippery surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slo...

Page 83: ...alertness reading the trail and avoiding quick sharp turns which can cause skids 4 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shift...

Page 84: ...Improper procedure could cause loss of control or overturn Whenever traveling uphill follow these precautions 1 Drive straight uphill 2 Avoid steep hills 15 maximum 3 Always check the terrain carefull...

Page 85: ...tle opening Opening the throttle suddenly could cause the ATV to flip over backwards 8 Never go over the top of any hill at high speed An obstacle a sharp drop or another vehicle or person could be on...

Page 86: ...the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 Slow down 2 Lean into the hill transferring your upper body weight uphill while keepin...

Page 87: ...eep hills 15 maximum 2 Shift body weight uphill Transfer your weight to the rear of the vehicle 3 Drive straight downhill 4 Slow down Excessive speed when traveling downhill can cause loss of control...

Page 88: ...phill 2 Shift the transmission to neutral 3 Shut off the engine 4 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 5 Staying uphill of the ATV turn...

Page 89: ...ATV from the uphill side keeping body weight uphill 8 Restart the engine 9 Squeeze the rear brake lever 10 Shift the transmission to forward gear 11 Release the parking brake and drive slowly controll...

Page 90: ...l or Incline Avoid parking on a hill or incline if possible If it s unavoidable follow these precautions 1 Stop the engine 2 Lock the parking brake 3 Always block the rear wheels on the downhill side...

Page 91: ...ting in a new area 2 Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches 3 Travel slowly and use extra caution when operating on unfami...

Page 92: ...th for your ATV is below the bottom of the footrests Follow these precautions when operating through water 1 Determine water depth and current before entering water 2 If crossing a stream choose a cro...

Page 93: ...l As soon as possible perform the inspections and maintenance services outlined in the periodic maintenance chart beginning on page 96 Engine oil gearcase oil and all grease fittings need special atte...

Page 94: ...e vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control which can result in serious injury or death Always follow these precautions when hauling cargo Place 1 3...

Page 95: ...r rope to secure the cargo Do not allow cargo or tie straps to hang over the edges of the racks Carry only small loads that fit on the racks Tall loads raise the center of gravity of the vehicle and m...

Page 96: ...with the USFS standard 5100 1c Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in...

Page 97: ...egal limits will void all manufacturer warranties and may violate laws governing the registration and operation of this vehicle Electromagnetic Interference This spark ignition system complies with Ca...

Page 98: ...under the seat Maintenance intervals in the following charts are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use...

Page 99: ...ARIS dealer Equivalent parts may be used for emissions related service Service and adjustments are critical If you re not familiar with safe service and adjustment procedures have a qualified dealer p...

Page 100: ...ys have an authorized POLARIS dealer or other qualified person perform these services Maintenance Chart Key Symbol Description Perform these operations more often for vehicles subjected to severe use...

Page 101: ...Ride Check list 70 Front suspension Daily Rear suspension Daily Tires Daily Brake lever travel Daily Brake system Daily Wheels fasteners Daily Frame fasteners Daily Engine oil level Daily Air filter...

Page 102: ...pect daily adjust and lubricate if needed 131 CVT housing if equipped Weekly Drain water as needed check often if operating in wet conditions 117 Break in Maintenance After first 10 hours of operation...

Page 103: ...ain and change the oil 110 Oil pre filter screen 40 12 M 400 640 Clean filter at every oil change clean annually if ATV is operated less than 10 hours 108 General lubrication 50 3 M 500 800 Lubricate...

Page 104: ...first Remarks See Page Hours Calendar Miles Km D Drive belt 50 6 M 500 800 See your POLARIS dealer D Brake pad wear 50 6 M 500 800 See your POLARIS dealer D Fuel System 100 12 M 1000 1600 Cycle key to...

Page 105: ...ct for wear routing security apply dielectric grease to connec tors subjected to water mud etc D Clutches drive and driven 100 12 M 1000 1600 Inspect clean replace worn parts D Front wheel bearings 10...

Page 106: ...eme Duty 10W 50 4 Cycle Oil See page 106 Gearcase Transmission Oil Level AGL Gearcase Lubricant Transmission Fluid See page 110 Drive Chain POLARIS Chain Lube or SAE 80 90 See page 131 Front Suspensio...

Page 107: ...105 Maintenance Lubrication Guide Grease Points Grease Points...

Page 108: ...mmends the use of POLARIS PS 4 Extreme Duty 4 Cycle engine oil for this vehicle Oil may need to be changed more frequently if POLARIS oil is not used Do not use automotive oil See page 162 for the par...

Page 109: ...an cloth 3 Reinstall the dipstick completely 4 Remove the dipstick and check the oil level Tip A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moistu...

Page 110: ...Allow it to idle for two to three minutes 4 Stop the engine CAUTION Hot oil can cause burns to skin Do not allow hot oil to contact skin 5 Place a drain pan under the engine crankcase 6 Remove the pr...

Page 111: ...lug 10 Reinstall the pre filter drain plug Torque to 11 ft lbs 15 Nm 11 Remove the dipstick Add 29 oz 850 ml of the recommended oil Do not overfill See the specifications section beginning on page 158...

Page 112: ...ge the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 96 POLARIS recommends the use of AGL Gearcase Lubricant Transmission Fluid See page 162 for the part numbers of...

Page 113: ...the drain plug Allow the oil to drain completely 5 Clean and reinstall the drain plug Torque to 14 ft lbs 19 Nm 6 Add the recommended oil Maintain the oil level at the bottom of the fill plug hole th...

Page 114: ...OLARIS recommended spark plugs or their equivalent Spark plug condition is indicative of engine operation The spark plug firing end condition should be read after the engine has been warmed up and the...

Page 115: ...ncorrect throttle body adjustments Wet Fouled Plug The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes...

Page 116: ...starting WILL result in serious engine damage Take the vehicle in for service before starting the engine Your POLARIS dealer can provide this service If this is not possible follow the vehicle immersi...

Page 117: ...e it with a new plug 6 Attempt to start the engine If necessary repeat the drying procedure 7 Take the vehicle in for service as soon as possible whether you succeed in starting it or not Your POLARIS...

Page 118: ...ads on components The CVT system rotates at high speeds creating large amounts of force on clutch components Extensive engineering and testing has been conducted to ensure the safety of this product H...

Page 119: ...ine Apply varying throttle for 10 15 seconds to expel the moisture and air dry the belt and clutches Do not hold the throttle wide open for more than 10 seconds 4 Allow the engine RPM to settle to idl...

Page 120: ...t beginning on page 96 Failure to heed these warnings could result in serious injury or death Do not perform service on the spark arrester while the system is hot Allow components to cool sufficiently...

Page 121: ...synthetic brush to clean the arrester screen A synthetic brush may melt if components are warm If necessary blow debris from the screen with compressed air 3 Inspect the screen for wear and damage Re...

Page 122: ...sale or later even at the consumer s request remove or adjust any speed limiting devices This vehicle has an adjustable speed control system that controls engine RPM and speed of the vehicle The spee...

Page 123: ...ottle Stop Speed Control System Use the following procedure to control how far the throttle opens 1 Loosen the jam nut 2 Turn the screw inward to reduce speed or outward to increase speed 3 Tighten th...

Page 124: ...le for smooth operation before riding Periodically check the throttle freeplay It should be kept between 1 16 and 1 8 1 5 3 2 mm If adjustment is required turn the adjustment nut until the freeplay fa...

Page 125: ...brakes at the intervals recommended in the Periodic Maintenance Chart beginning on page 96 If the freeplay isn t at specification adjust the freeplay as outlined on the following pages Brake Freeplay...

Page 126: ...e front of the vehicle by placing a suitable stand under the frame The front tires should be slightly off the ground 4 While rotating the left front wheel tighten the upper front brake adjuster nut on...

Page 127: ...ront brake adjuster nut on the right hand control 7 When you begin to feel a slight drag in wheel rotation loosen the adjuster nut one full turn 8 Verify that the right hand brake functions correctly...

Page 128: ...e rear tires should be slightly off the ground 4 While rotating the rear wheels tighten the rear brake wing nut at the rear brake drum 5 When you begin to feel a slight drag in wheel rotation loosen t...

Page 129: ...on the preceding pages use the following information to determine when to service the brakes Service the brakes when brake lever travel reaches the total lever travel measurement listed in the table b...

Page 130: ...djust tie rod alignment All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility 1 Position the vehicle on a level surface 2 Place the handlebars...

Page 131: ...nt rim The rear measurement should be 1 16 1 8 2 3 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 8 to 1 4 3 6 mm toe out alignment 5 Repeat the measurement...

Page 132: ...POLARIS dealer or other qualified service facility before operating the vehicle Camber and Caster The camber and caster are non adjustable Shock Spring Adjustment The front and rear shock absorber spr...

Page 133: ...y or wet conditions See page 162 for the part numbers of POLARIS products NOTICE Washing the drive chain with a high pressure washer or gasoline can cause premature wear and drive chain failure Don t...

Page 134: ...he strap around the axle and rear bumper tube 3 Tighten the strap until a straight line can be drawn from the rear axle to the gearcase output shaft intersecting the swing arm pivot This establishes t...

Page 135: ...lock nut 3 Turn the chain adjuster clockwise to 1 4 1 2 6 12 mm deflection 4 Tighten the chain adjuster lock nut to 18 ft lbs 25 Nm Hold the adjuster stud securely while tightening the nut to avoid b...

Page 136: ...ing clips and remove the cover 3 Remove the foam air filter Wash the foam filter in warm soapy water then rinse and let dry If the filter is damaged install a new foam filter 4 Apply a commercially av...

Page 137: ...or sediments in the air box 6 Reinstall the filter and air box cover Secure the clips 7 Reinstall the seat NOTICE Never operate the ATV with the filter element removed Dirt will enter the engine caus...

Page 138: ...edures exactly or see your POLARIS dealer or other qualified service person for service The handlebars can be adjusted for rider preference 1 Remove the pod to access the handlebar bolts Loosen the fo...

Page 139: ...or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death Always follow all tire maintenance procedures as outlined in this manual and...

Page 140: ...worn to 1 8 3 mm or less Wheel Removal 1 Stop the engine and lock the parking brake 2 Loosen the wheel bolts slightly 3 Elevate the side of the vehicle by placing a suitable stand under the footrest...

Page 141: ...n the correct position on the wheel hub Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation 3 Install the wheel bolts and finger tighten them 4 L...

Page 142: ...ve a cotter pin installed Your POLARIS dealer can assist Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by...

Page 143: ...doesn t work the lamp may need to be replaced 1 Remove the two screws securing the lens cover Remove the lens cover 2 Remove the lamp and replace it with a new recommended lamp 3 Test the light for p...

Page 144: ...er or pod to access the lamps 2 Remove the indicator wire connections from the harness 3 Remove the nut from the back side of the indicator lamp 4 Remove the lamp 5 Apply dielectric grease to the sock...

Page 145: ...the light assembly 4 Press the lamp retainer inward and turn it counter clockwise to remove it Note the position of the lamp positioning tab then carefully pull the lamp out 5 Install the new lamp Mak...

Page 146: ...y in your POLARIS ATV is a sealed battery The sealing strip cannot be removed Never add water to this type of battery Keep the battery terminals and connections free of corrosion If cleaning is necess...

Page 147: ...intenance Battery Battery Removal 1 Remove the battery hold down strap 2 Disconnect the black negative battery cable first 3 Disconnect the red positive battery cable next 4 Lift the battery out of th...

Page 148: ...lt in a shorter life It can also hinder vehicle performance If recharging is necessary use a 5 amp battery charger 1 Set the battery in its holder 2 Coat the terminals with dielectric grease or petrol...

Page 149: ...g storage and recharge as needed to maintain a full charge Cleaning Keeping your ATV clean will not only improve its appearance but it can also extend the life of various components NOTICE High water...

Page 150: ...lower parts last 2 Rinse with clean water frequently 3 Dry surfaces with a chamois to prevent water spots Washing Tips Avoid the use of harsh cleaners which can scratch the finish Do not use a power w...

Page 151: ...ls Avoid directing the water stream at the following items Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals If warning and safety labels are damaged contact your...

Page 152: ...ish on your POLARIS vehicle Follow the instructions on the container Polishing Tips Avoid the use of automotive products some of which can scratch the finish of your vehicle Always use clean cloths an...

Page 153: ...he vehicle as recommended See page 147 Battery Storage Remove the battery from the vehicle ensure that it s fully charged and store it out of the sun in a cool dry place Check battery voltage each mon...

Page 154: ...quivalent fuel treatments or stabilizers Follow the instructions on the container for the recommended amount Carbon Clean removes water from fuel systems stabilizes fuel and removes carbon deposits fr...

Page 155: ...hes the injectors Stop the engine 2 Remove the spark plug and add 2 3 tablespoons of engine oil To access the plug hole use a section of clear 1 4 hose and a small plastic squeeze bottle filled with t...

Page 156: ...be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 6 If POLARIS fuel system additive is not used fuel tank fuel lines and injectors shoul...

Page 157: ...r Filter Air Box Inspect and clean or replace the pre cleaner and air filter Clean the air box Drain the sediment tube Fluid Levels Inspect fluid levels Change fluids as recommended in the Periodic Ma...

Page 158: ...e sure tire pressure is at specification 2 Using suitable supports under the frame raise the vehicle slightly so that the tires are not touching the ground 3 Be sure the storage area is well ventilate...

Page 159: ...ame of the ATV to the transporting unit securely with suitable straps or rope The rack bumper or handlebars do not offer enough support for tie down while transporting 3 Wrap the front tie strap throu...

Page 160: ...el Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Engine type 4 Stroke Displacement 111cc Cooling Air Cooled Bore x Stroke 61 mm x 57 8 mm Alternator Output 80 watts Compr...

Page 161: ...ap NGK CR6HSA 0 6 0 7 mm Drive System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel Front Rear Brakes Drum P...

Page 162: ...heel Base 41 5 105 cm Ground Clearance 4 10 cm at swing arm 7 7 19 5 cm at frame Engine type 4 Stroke Displacement 111cc Cooling Air Cooled Bore x Stroke 61 mm x 57 8 mm Alternator Output 80 watts Com...

Page 163: ...System Automatic CVT Final Drive Chain Front Suspension Single A arm with 5 12 7 cm of travel Rear Suspension Swing arm with 6 15 2 cm of travel Front Rack Capacity 15 lbs 7 kg Rear Rack Capacity 30...

Page 164: ...Duty Synthetic 10W 50 4 Cycle Oil gal 3 8 l Gearcase Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant Transmission Fluid qt 95 l 2878069 AGL Full Synthetic Gearcase Lubricant Tran...

Page 165: ...logged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect...

Page 166: ...arger Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten Possible Cause Solution Poor quality or low octane fuel Replace with reco...

Page 167: ...e Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 8 VDC Kinked or...

Page 168: ...Fuel Mixture Cause Solution Low or contaminated fuel Add or change fuel clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Cl...

Page 169: ...defective spark plug wires Your POLARIS dealer can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low batt...

Page 170: ...ransfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations REGISTRATION At the time of sale the Warr...

Page 171: ...ed improperly maintained or used for racing competition or purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine...

Page 172: ...s environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Wheels and tires Finished and unfinished surfaces Susp...

Page 173: ...of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expens...

Page 174: ...ORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED...

Page 175: ...Service Bulletin repairs must be done by an authorized POLARIS dealer If you move or are traveling within the country where your product was purchased Warranty and Service Bulletin repairs may be requ...

Page 176: ...r product in your new country You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that y...

Page 177: ...ucts that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service cove...

Page 178: ...was purchased will continue to be covered by the Limited Warranty Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance they will contact th...

Page 179: ...00 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions c...

Page 180: ...sibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related compone...

Page 181: ...the evaporative emission control system Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valve...

Page 182: ...ERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION O...

Page 183: ...he scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for...

Page 184: ...th position of the model number e g R16RTE87B The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violati...

Page 185: ...to your dealer each time your vehicle is serviced This will provide you and future owners with an accurate log of maintenance and services performed DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED...

Page 186: ...184 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS 100 Hours 120 Hours 150 Hours...

Page 187: ...185 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 188: ...186 Maintenance Log DATE SERVICE INTERVAL TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 189: ...y 9 CVT Drying 117 CVT System 116 Cylinder Head Torque 114 D Daytime Running Lights 143 Drive Chain 131 Drive Chain Slack 132 Drive Chain Slack Adjustment 133 Driving Downhill 85 Driving in Reverse 79...

Page 190: ...Oil Engine 106 Operator Restrictions 13 P Parking on a Hill or Incline 88 Periodic Maintenance Chart 96 103 Polaris Products 162 Polishing 150 Pre Ride Inspection 70 71 R Restrictions Age 13 Riding Ge...

Page 191: ...tle Cable Adjustment 122 Throttle Control 41 Throttle Lever 61 Tire Tread Depth 138 Tires 137 Toe Alignment 128 129 Transmission Oil 110 111 Transporting the ATV 157 Turning Around on a Hill 86 87 V V...

Page 192: ......

Page 193: ...skills or the conditions S on public roads a collision can occur with another vehicle S with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS S use proper...

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