Polaris Trail Blazer Owner'S Manual Download

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MAINTENANCE AND LUBRICATION

Lights

When servicing a halogen lamp, don’t touch the lamp with bare

fingers. Oil from your skin leaves a residue, causing a hot spot that

will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death.

Headlight and taillight lenses become dirty during normal

operation. Wash the headlights frequently to maintain lighting

quality.
Hot components can cause serious burns to skin. Do not service

the headlamps until they’ve cooled sufficiently.

Headlight Lamp Replacement

1. Remove the front cover and unplug the light harness.
2. Remove the rubber cap from the back of the headlight to reveal the

retention screw.

3. Remove the small phillips head screw, and carefully remove the

bulb from the housing.

4. Insert the new bulb into the housing and reinstall the retention

screw. Reinstall the rubber cap.

5. Reconnect the light harness and reinstall the cover.
6. Adjust the headlight aim if necessary.

Summary of Contents for Trail Blazer

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Page 3: ...hed to the owner s manual on the next page If you cannot locate this card or if it has been removed please call 1 800 342 3764 for assistance The engine exhaust from this product contains chemicals known to cause cancer birth defects or other reproductive harm WARNING ...

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Page 5: ... minor discrepancies may result between 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 or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited Printed in U S A 2005...

Page 6: ...r 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 Technician Your Polaris dealer knows your vehicle best and is interested in your total satisfaction ...

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Page 8: ...ME 3 VEHICLE IDENTIFICATION NUMBERS 7 SAFETY 8 FEATURES AND CONTROLS 32 OPERATION 44 EMISSION CONTROL SYSTEMS 63 MAINTENANCE AND LUBRICATION 64 SPECIFICATIONS 103 POLARIS PRODUCTS 106 TROUBLESHOOTING 107 WARRANTY 111 INDEX 114 ...

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Page 10: ...move 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 so if both keys are lost the ignition switch must be replaced Vehicle Model Number Frame VIN 1 Engine Serial Number right front side of engine crankcase Key Number 2 1 31XX 2 ...

Page 11: ...Read and understand your owner s manual which includes valuable information about all aspects of your vehicle including safe operating procedures Safety Training When you purchased your new ATV your dealer offered a hands on safety training course that covers all aspects of vehicle safety You were also provided with printed materials that explain safe operating procedures You should review this in...

Page 12: ... your vehicle or in this manual alerts you to the potential for personal injury WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle CAUTION A caution indicates a situation that may result in damage to the vehicle NOTE A...

Page 13: ... including a dirt or gravel road S Never operate an ATV without wearing an approved helmet that fits properly Always wear eye protection goggles or face shield gloves 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 condition...

Page 14: ... 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 15: ...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 16: ...se 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 WARNING 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...

Page 17: ... allow the operator to shift position as needed during operation It is not intended for carrying passengers WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces including sidewalks paths parking lots and driveways 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 ac...

Page 18: ... POTENTIAL HAZARD Operating this ATV without wearing an approved helmet eye protection and protective clothing WHAT CAN HAPPEN Operating an ATV without an approved helmet increases 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 AVOI...

Page 19: ...efore or 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 WARNING 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 op...

Page 20: ...er stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating Failure to properly maintain the ATV WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage HOW TO AVOID THE HAZARD Always inspect your ATV before each use to make sure it s in safe operating condition Always follow the inspection and maintenance procedures...

Page 21: ... into contact with the rear wheels and lead to accident or injury HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation WARNING POTENTIAL HAZARD Failure to use extra caution when operating the ATV on unfamiliar terrain WHAT CAN HAPPEN Unfamiliar terrain may contain hidden rocks bumps or holes that could cause loss of control or ...

Page 22: ...te 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 POTENTIAL HAZARD Turning improperly WHAT CAN HAPPEN Improper turns could cause loss of control and lead to a collision or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for ...

Page 23: ...oper hill climbing could cause loss of control or overturn HOW TO AVOID THE HAZARD Always follow proper procedures for climbing hills as described in the owner 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 w...

Page 24: ...ures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 54 Always check the terrain carefully before 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...

Page 25: ...pt to turn 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 55 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 weigh...

Page 26: ...hen fully 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 ...

Page 27: ...anual WARNING 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 caution to reduce the chance of skidding or sliding out of control WARNING POTENTIAL HAZARD Improperly operating in reverse WHAT CAN HAPP...

Page 28: ...ents 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 WARNING POTENTIAL HAZARD Operating this ATV with improper tires or with improper or uneven tire pressure WHAT CAN HA...

Page 29: ...ore information WARNING POTENTIAL HAZARD Overloading the ATV or carrying towing cargo improperly WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling which could lead to loss of control or an accident HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV Cargo should be properly distributed and securely attached Reduce speed when carrying cargo or pulli...

Page 30: ...entire vehicle for possible damage including but not limited to brakes throttle and steering systems WARNING Safe operation of this rider active vehicle requires good judgement and physical skills Persons 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 combustibl...

Page 31: ...es To prevent flipover on hilly terrain when going up or down use throttle and brakes gradually DREVERSE operation can bedangerous evenat lowspeeds Steeringbe comes difficult To prevent flipover avoid sudden braking or sharp turns DUse OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle DPARKING BRAKE may relax when used for ...

Page 32: ...ocations Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate ALWAYS 7172560 WARNING ...

Page 33: ...L TERRAIN VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS 7171492 CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS Canadian Certification Decal Reverse Speed is limited Reverse override is controlled by the override switch See your Owner s Manual OVERRIDE SWITCH 7079906 Under Seat Operating this ATV if you are under the age of 16 increases y...

Page 34: ...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 35: ...osition Release the key when the engine starts NOTE Turning off the main switch will shut off all electrical power to the vehicle including the lights WARNING Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death Always remove the ignition key when the vehicle is not in use Engine Stop Switch 3 The engine will not start or run when the sw...

Page 36: ... Throttle Lever Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever 1 is spring loaded Engine speed returns to idle when the lever is released This ATV is equipped with Polaris Electronic Throttle Control ETC 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 rele...

Page 37: ...nd darkness Light Switches The light switch is located on the left handlebar 1 It s used to turn the lights on and off NOTE The lights won t work unless the key is in the ON position and the shut off switch is in the RUN position Indicator Lights With the engine running 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...

Page 38: ...n the diaphragm extends into the reservoir as fluid level drops If the fluid level is low and the diaphragm is not extended a leak is likely and the diaphragm should be replaced Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation We recommend the use of Polaris DOT 3 brake fluid Do not overfill 3 If the fluid level is low add DOT 3 bra...

Page 39: ...ake lever 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 WARNING Operating the ATV with a spongy brake lever can result in loss of braking which could cause an accident Never ...

Page 40: ... 2 forward to engage the brake Release the brake lever 3 To release the parking brake lock squeeze and release the brake lever It will return to its unlocked position Important Safeguards S The parking 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 opti...

Page 41: ...d serious injury or death The auxiliary brake 1 is located on the inside of the right floor board and is operated by the right foot The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative If the rear wheels slide while using the auxiliary brake reduce brake pedal pressure to brake the rear wheels without skidding Check the brake fluid level frequently...

Page 42: ...ed 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 the specifications se...

Page 43: ...ored S Do not overfill 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 consciousness or death in a short time S Turn the fuel valve off whenever the ATV is stored or parked WARNING The en...

Page 44: ...nd 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 The oil injection tank filler cap 1 is located on the front of the vehicle Refer to the specifications section beginning on page 103 for capacities 1 ...

Page 45: ...d N Neutral R Reverse CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage To change gears stop the vehicle and with the engine idling move the lever to the desired gear Whenever the ATV is left unattended always place the transmission in gear and lock the parking brake 1 F N R ...

Page 46: ... 2 firmly and pull slowly so you can feel the engine strokes NOTE Every other stroke will be a compression stroke and will make the rope harder to pull When a compression stroke is found continue pulling the rope just until the engine rolls past the stroke then stop pulling immediately 5 Allow the recoil rope to rewind into the recoil assembly then pull the rope abruptly and forcefully to start th...

Page 47: ...e engine Perform the following procedures carefully CAUTION Excessive heat build up during the first three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Use of any oils other than those recommended by Polaris may cause serious engine damage We recommend the use of Polaris 2 cycle oil ...

Page 48: ...the oil tank with the recommended oil 3 Drive slowly at first Vary the throttle positions 4 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist on page 46 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 pump is functioning properly If the level has not droppe...

Page 49: ...Inspect condition and pressure 82 Wheels fasteners Inspect ensure fastener tightness 81 Frame nuts bolts fasteners Inspect ensure tightness Fuel and oil Ensure proper levels 71 Coolant level if applicable Ensure proper level Coolant hoses if applicable Inspect for leaks Throttle Ensure proper operation 33 78 Indicator lights switches Ensure operation 34 Engine stop switch Ensure proper operation 3...

Page 50: ... when the knob is pulled completely out The choke is off when the knob is pushed completely in The choke can be adjusted gradually depending on how much choke is needed for starting Be sure the choke is off during operation as excess fuel washing into the engine oil will increase wear on engine components 3 Move the engine stop switch to RUN NOTE Do not press the throttle while starting the engine...

Page 51: ...n the fuel tank valve to ON sit on the vehicle and turn the engine stop switch to RUN 3 If the engine has cooled to a point where it does not readily start intermittent use of the choke pulled half way out may be necessary NOTE If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 4 Release the throttle lever immediately after the engine starts I...

Page 52: ...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 53: ...tion 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 sharp...

Page 54: ...e trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of control accident and serious injury or death Never apply the brakes during a skid Do not operate on excess...

Page 55: ...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 56: ...idehilling can be a dangerous type of driving and should be avoided if at all possible If you do enter into a situation where sidehilling is necessary follow these precautions 1 Slow down 2 Lean into the 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 NOTE If the vehicle begins to tip qu...

Page 57: ... 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 WARNING Excessive speed can cause loss of control and lead to serious injury or death Always operate slowly when traveling downhill ...

Page 58: ...g brake while keeping body weight uphill 2 Leave transmission in forward and shut off the engine 3 Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill 4 Staying uphill of the vehicle turn the handlebars full left 5 While holding the brake lever release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointi...

Page 59: ...ng 2 Choose a crossing where both banks have gradual inclines 3 Proceed slowly avoiding rocks and obstacles if possible 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal After running the vehicle in water it s critical to have it serviced as outlined in the maintenance chart See page 64 The following areas need special attention engine oil trans...

Page 60: ...re starting the engine 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 it s impossible to t...

Page 61: ... the terrain you re traveling on Be constantly alert for hazards such as logs rocks and low hanging branches WARNING Severe injury or death can result if your vehicle comes in contact with a hidden obstacle Not all obstacles are immediately visible Travel with caution in unfamiliar terrain ...

Page 62: ...s or people behind the vehicle When it s safe to proceed back slowly Do not use the override switch unless additional power is required for vehicle movement Use with caution Avoid backing on inclines and avoid turning at sharp angles 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...

Page 63: ...ever exceed the weight capacities outlined in the specifications section of the owner s manual and on the safety decals Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions Do not obstruct the headlight beam with cargo 2 3...

Page 64: ...MUST BE SECURED BEFORE OPERATING Unsecured 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 C...

Page 65: ...d parking on an incline if possible If it s unavoidable follow these precautions 1 Turn the engine off 2 Place the transmission in gear 3 Set the parking brake 4 Always block the rear wheels on the downhill side See illustration 5 Shut off the fuel supply ...

Page 66: ...e level requirements Spark Arrestor Your Polaris vehicle has a spark arrestor that was tested and approved in accordance with the USDA Forest Service Standard 5100 1C Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands Electromagnetic Interference This spark ignition system complies with Canadian ICES 002 ...

Page 67: ...erage vehicle speed of approximately 10 miles per hour Vehicles subjected to severe use must be inspected and serviced more frequently Severe Use Definition S Frequent immersion in mud water or sand S Racing or race style high RPM use S Prolonged low speed heavy load operation S Extended idle S Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold...

Page 68: ...e E Engine oil level Pre Ride E Air filter pre filter Daily Inspect clean often E Air box sediment tube Daily Drain deposits when visible Headlamp Daily Check operation Tail light Daily Check operation apply dielectric grease if replacing E Air filter main element Weekly Inspect replace as needed Recoil housing Weekly Drain water as needed check often if operating in wet conditions J Brake pad wea...

Page 69: ...oil change at one month E Oil filter change 100 H 6 M 1000 1600 Replace with oil change J E Valve clearance 100 H 12 M 1000 1600 Inspect adjust J E Fuel system 100 H 12 M 1000 1600 Check for leaks at tank cap lines fuel valve filter pump carburetor replace lines every two years J E Fuel filter 100 H 12 M 1000 1600 Replace yearly Engine mounts 100 H 12 M 1000 1600 Inspect Exhaust muffler pipe 100 H...

Page 70: ...Change every two years Spark arrestor 300 H 36 M 3000 4800 Clean out E Idle speed Adjust as needed J Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use E Emission Control System Service California J Have an authorized Polaris dealer perform these services ...

Page 71: ...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 72: ...pecial Item Lube Method Engine Polaris Injection Oil Fill oil tank See page 41 Brakes DOT 3 fluid only Maintain level between fill lines See page 35 Drive chain s O ring chain lube or SAE 80 90 Lubricate as often as required Before each ride in wet conditions Transmission AGL Synthetic Gear case Lube See Page 72 1 Ball Joint L Grease Locate fitting on back side of struts and grease with grease gun...

Page 73: ...hrough the life of the unit Your dealer will be able to assist you with that selection based on your operating conditions and riding style Never mix Polaris premium 2 cycle oils with any other brand of oil including Polaris Nature Oil Biodegradable oil Their incompatibility could result in engine damage For best performance we recommend that you choose one oil for your ATV then continue to use it ...

Page 74: ...d forward of the headlight Check the oil before each use of the vehicle Refill the oil when refueling 1 Position the ATV on a level surface 2 Remove the oil tank cap and inspect the oil level in the tank 3 Add oil as needed to bring the level to the full mark Do not overfill 4 Reinstall the oil tank cap 1 ...

Page 75: ...he recommended gearcase oil to bring the level within the safe operating range on the dipstick 4 Reinstall the dipstick Transmission Oil Change 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 removal of the drain plug C 4 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 5 ...

Page 76: ...ecommended oil See page 106 for the part numbers of Polaris products 2 Loosen the bleeder screw one full turn Allow oil to flow from the bleed screw for five to ten seconds then tighten the bleed screw CAUTION Allowing the engine to run while the bleed screw is loose will result in loss of oil which will cause serious engine damage Always retighten the bleed screw if it s been loosened for service...

Page 77: ...16 32 cm of throttle lever travel before the throttle slide starts to open 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 m...

Page 78: ...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 Install new brake pads when pads are worn to 3 64 1 cm Auxiliary Brake The 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 activate...

Page 79: ...e used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands 1 in front of the vehicle perpendicular to the rear tires See 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 th...

Page 80: ...nd 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 ...

Page 81: ...ar to the desired height Be sure the handlebars do not contact 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 Throttle Cable Freeplay Throttle cable freeplay is adjusted at the handlebar 1 Slide the boots 1 off the inline cable ...

Page 82: ...oor performance overheating or engine damage See your Polaris dealer for more information about jetting the ATV for conditions in your area 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 and lock the parking brake 3 Adjust t...

Page 83: ...scribed on the decal on your ATV and in your owner s manual Always use original equipment size and type when replacing tires Make sure the wheels are installed properly Always replace tires when the tread depth measures 1 8 3 cm or less Wheel Removal 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 pla...

Page 84: ... the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation 3 Install the wheel nuts and finger tighten On vehicles with tapered rear wheel nuts make sure the tapered ends of the nuts fit into the tapers on the wheels 4 Lower the vehicle to the ground 5 Torque the wheel nuts according to the wheel nut torque specifications chart Wheel Nut Torque Specific...

Page 85: ...erating 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 WARNING 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 Maint...

Page 86: ... the stone guard to rear sprocket clearance at 1 8 3 cm 4 Regularly lubricate the drive chain with Polaris chain lube or SAE 80 90 lube See page 106 for the part numbers of Polaris products CAUTION Washing the drive chain with a high pressure washer or gasoline can cause damage to the o rings causing premature wear and drive chain failure Don t use a high pressure washer or gasoline to clean the d...

Page 87: ...k in three different locations by moving the vehicle slightly forward Measure the chain slack at the tightest of the three positions At this point the chain should have 3 16 3 8 48 cm 95 cm deflection Use the following procedure if adjustment is required 1 Loosen the chain guide 2 Loosen the two eccentric locking bolts 1 3 Loosen the caliper mounting bolt located on the left side of the swing arm ...

Page 88: ...ines without the hitch and 45 ft lbs 61 Nm for machines with a hitch 3 Tighten the caliper mount bolt to 15 ft lbs 20 Nm 4 Remove the pin punch 5 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 6 Position the chain guide to allow 1 8 3mm clearance and tig...

Page 89: ... 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 Check and replace the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 65 NOTE Always replace the main filter when it becom...

Page 90: ...aintain lighting quality Hot components can cause serious burns to skin Do not service the headlamps until they ve cooled sufficiently Headlight Lamp Replacement 1 Remove the front cover and unplug the light harness 2 Remove the rubber cap from the back of the headlight to reveal the retention screw 3 Remove the small phillips head screw and carefully remove the bulb from the housing 4 Insert the ...

Page 91: ...ght 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 mark placed on the wall NOTE Include rider weight on the seat when measuring 5 Adjust the beam to the desired position by turning the adjustment screws 1 S Turning the right screw clockwise moves the intense spot of light up and to the left S Turning the left screw clockwise ...

Page 92: ...nd install the 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 indic...

Page 93: ...nsulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black ...

Page 94: ... is present 3 Turn the fuel valve off 4 Remove the spark plug 5 Remove the bowl drain 1 6 Remove the crankcase drain screw at the left front of the engine bottom 7 Turn the engine over several times using the electric start 8 Dry the spark plug and reinstall or replace it with a new plug 9 Reinstall the bowl drain 10 Reinstall the crankcase drain screw 11 Turn the fuel valve on 12 Attempt to start...

Page 95: ...der the vehicle while it s inclined 1 Remove the arrestor clean out plug 1 from the bottom of the muffler 2 Place the transmission in neutral and start the engine 3 Purge carbon from the system by momentarily revving the engine several times 4 If carbon is expelled cover or plug the exhaust outlet 2 and rap on the pipe around the cleanout plug while revving the engine several more times 5 If parti...

Page 96: ... also be done before storing the ATV Water will enter the recoil housing if the starter handle is disengaged from the rope guide when under water The recoil handle must be behind 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 1 ...

Page 97: ...running at only about 1500 RPM with an engagement speed of about 1400 RPM Whenever operating this close to the engagement point the engine may be running at a speed too low to provide the adequate pinch needed to prevent incomplete engagement Incomplete engagement creates excessive heat that can destroy belts and clutch covers In some cases excessive clutch wear and damage may result If the ATV wi...

Page 98: ...ended maintenance procedures See your dealer as outlined in the owner s manual This PVT system is intended for use on Polaris products only Do not install it in any other product Always make sure the PVT housing is securely in place during operation PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the following instructions to dry it out before opera...

Page 99: ...itive battery cable next 4 Lift the battery out of the ATV Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 97 before installing the battery 1 Ensure th...

Page 100: ...ady filled with electrolyte and has been sealed and fully charged at the factory Do not ever pry the sealing strip off or add any other fluid to this battery The single most important thing about maintaining a sealed battery is to keep it fully charged Since the battery is sealed and the sealing strip cannot be removed you must use a voltmeter or multimeter to measure DC voltage For a refresh char...

Page 101: ...standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 mos from date of manufacture None required 75 100 12 5 12 8 volts May need slight charge if no charge given check in 3 months 3 6 hours 50 75 12 0 12 5 volts Needs charge 5 11 hours 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At...

Page 102: ...afety 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 warning labels and decals NOTE Grease all zerk fittings immediately after washing and allow...

Page 103: ...ns the fuel system the combustion chamber and the exhaust ports It also prevents bacterial growth and promotes better starting after the storage period 1 Fill the fuel tank with fuel and add Polaris Carbon Clean or Fuel Stabilizer Follow the instructions on the container for the recommended amounts 2 Start the engine and allow it to run for 15 20 minutes so the stabilizer can disperse through the ...

Page 104: ...5 Treat the fuel system with Polaris Carbon Clean 6 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant Follow lubrication guidelines in the maintenance section of the service or owner s manual to completely grease and lubricate the entire vehicle with Polari...

Page 105: ...as are more susceptible to corrosion if not properly cleaned Clean chrome wheels more often if they re exposed to salt or other corrosive elements Removing Corrosion If light rust is found on the chrome finish use steel wool 0000 OTT grade to remove it Gently rub the affected areas with the steel wool until the corrosion has been removed Clean and polish the wheel as outlined above Transporting an...

Page 106: ... Ground Clearance 5 5 14 cm Height 47 in 119 4 cm Length 75 in 190 5 cm Seat Height 34 in 86 4 cm Dry Weight 461 lbs 209 1 kg Wheel Base 48 in 121 9 cm Width 46 in 116 8 cm Engine Cooling Engine Model Number Type EC 25PFE 154 2 Cycle Single Cylinder Lubrication Oil Injection Bore x Stroke 72 x 60 Displacement 244cc Compression Ratio 6 1 1 Effective Engine Cooling Air Alternator Output 150 watts 40...

Page 107: ...nsion McPherson Strut w 8 2 20 8 cm travel Rear Suspension Progressive Rate w 10 5 26 7 cm travel Shock Adjustment CAM Front Brake Hydraulic Disc Rear Brake Hydraulic Disc Auxiliary Brake Hydraulic Disc Park Brake Hydraulic lock all wheel Features Headlight 1 Single Beam 55 w Taillight 8 26 w Brake Light 26 9 w Battery 12V 14 AH DC Plug In Rear Accessory DC Socket Forward Accessory Electric Start ...

Page 108: ...40 130 120 110 1800 2700 6000 9000 125 120 110 100 2700 3700 9000 12000 115 110 100 95 Turn air screw out 1 2 turn CCW from seat Raise needle clip 1 position to lower jet needle Clutching Chart Altitude Shift Weight Drive Clutch Spring Driven Clutch Spring Helix Spring Setting Meters Feet 0 1800 0 6000 G 5630514 Blue Green 7041157 Red 7041198 40 5131446 2 2 1800 3700 6000 12000 F 5630515 Blue Gree...

Page 109: ...ricants 2873602 Premium AGL Synthetic Gearcase Lube qt 2873603 Premium AGL Synthetic Gearcase Lube gal 2870465 Pump for Gallon Jug Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871312 Grease Gun Kit 2871329 Dielectric Grease Nyogelt 2872073 Chain Lube 6 25 oz aerosol 2872348 Chain Lube ...

Page 110: ...le and prevent belt burning Slow and easy clutch en gagement Use the throttle quickly and effectively for efficient enga gement Towing pushing at low RPM low ground speed Install a one tooth smaller counter shaft sprocket Stuck in mud or snow Carefully use fast aggressive throttle application to en gage clutch WARNING Excessive throttle may cause loss of control and vehicle overturn Climbing over ...

Page 111: ...uel 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 plugs Clogged fuel filte...

Page 112: ...se 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 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 113: ...ective spark plug wires 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 8 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttl...

Page 114: ...RANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship This warranty does not cover accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any ATV that has been al tered structurally modified neglected improperly maintained used fo...

Page 115: ...ou 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 selling dealer however you may use any Polaris Servicing Dealer to perform war ranty service Please work with your dealer to resolve any warranty issues Should your dealer require any additional assistance the...

Page 116: ...rized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to per form the warranty repair If You Move If you move to another country be sure to contact Polaris Customer Assistance and the customs department of the destination country before...

Page 117: ...er Obstacles 58 Driving Procedures 49 Driving Safely 49 62 Driving Through Water 56 57 Driving Uphill 52 E Electrical Switches 32 EMISSION CONTROL SYSTEMS 63 Engine Fogging 101 Engine Oil Check 71 Equipment Modifications 12 F FEATURES 32 43 Filter Systems 86 Front Wheel Hub Tightening 82 Fuel Filter 39 Fuel Safety 40 Fuel Stabilizer 100 Fuel Tank 39 Fuel Valve 39 G Gear Selector 42 H Handlebars 78...

Page 118: ... Plugs 90 SPECIFICATIONS 103 105 Starting a Cold Engine 47 Starting a Warm Engine 48 Starting the Engine 47 48 Steering Assembly 77 Stop Switch 32 Storage Tips 100 102 T TABLE OF CONTENTS 5 Taillight Brakelight Lamp Replacement 89 Throttle Cable Freeplay 78 Throttle Lever 33 Tire Tread Depth 82 Toe Alignment 76 Transmission Gear Selector 42 Transmission Oil Change 72 Transmission Oil Check 72 Tran...

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