Polaris Universal ATV 2000 Owner'S Safety And Maintenance Manual Download Page 133

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INDEX

125

Engine Cooling System

45-46

. . . . . . . . . .

Air Cleaner

92-95

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

Air Filters

93-95

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

All Wheel Drive

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

Backing Up

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

Battery Installation

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

Battery Maintenance

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

Battery Removal

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

Brake, Auxiliary

41 and 98

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

Brake, Front

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

Brake, Parking

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

Brake, Rear

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

Brakes, Front

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

Brakes, Rear

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

Break In Period

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

Break In Period -- 4 Cycle

56-57

. . . . . . . .

Breather Filter

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

Camber and Caster

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

Carburetor Adjustment (4 Cycle)

103

. . .

Carburetor Adjustment (2 Cycle)

102

. . .

Carburetor Adjustments

121

. . . . . . . . . . .

Cargo Weight Distribution

. . . . . . . . . .

Carrying Loads

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

Chain Adjustment

112

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

Choke Adjustment (4 Cycle)

102

. . . . . . .

Choke Adjustment Procedure

101

. . . . . .

Choke Lever

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

Cleaning Your ATV

120

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

Control and Parts Functions

35-54

. . . . . .

Coolant Level

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

Coolant Level Inspection

. . . . . . . . . . .

Counter Balance Lubrication

108

. . . . . . .

Counter Balance Oil Changing

Procedure

108

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

Crossing Streams

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

Cylinder Head Torque

104

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

Daily Pre-ride Inspection

14 and 61

. . . . .

Demand 4 Drive

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

Disengaging Wheel Hubs

. . . . . . . . . .

Draining Recoil Housing

. . . . . . . . . . .

Drive Chain Adjustment

111

. . . . . . . . . . .

Engine Choke Adjustment

103

. . . . . . . . .

Engine Choke Adjustment (400)

101

. . . .

Engine Electrical Switches

. . . . . . . . .

Engine Idle Rpm Adjustment

102-103

. . .

Filter Change

49-50

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

Front Gearcase Lubrication

107

. . . . . . . .

Front Wheel Hub Tightening

. . . . . . . .

Fuel Filter

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

Fuel Safety

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

Fuel System

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

Gearcase Oil Changing Procedure

107

. .

Handlebar Adjustment

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

Headlight Adjustment

113-117

. . . . . . . . . .

Headlight Lamp Replacement

113-117

. . .

Indicator Lamp Replacement

119

. . . . . . .

Indicator Lights

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

Light Switches

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

Load Capacity

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

Lubricant, 2cycle

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

Lubrication Recommendations

82-86

. . . .

Main Switch

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

Battery

73-74

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

Maintenance

76-121

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

Maintenance Record

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

Maintenance Schedule

79-81

. . . . . . . . . . .

Making Turns

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

Noise Control System

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

Oil Change

49-50

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

Oil Filter

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

Oil Pump Adjustment

99-100

. . . . . . . . . .

Oil Pump Bleeding

100

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

Oil System

47-49

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

Operation Warnings

15-33

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

Parking On An Incline

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

Power Pig Tail

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

Premium 4 Synthetic Lubricant

. . . . . .

PVT System

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

Rear Spring Adjustment

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

Recoil Starter

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

Riding

62-72

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

Riding Gear

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

Riding On Slippery Surfaces

. . . . . . . .

Safety Warning and Operation

Decals

3-13

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

Side Panel Removal

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

Sidehilling

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

Spark Arrestor

76-77

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

Spark Plugs

104

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

Starting A Cold Engine

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

Starting The Engine

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

Steering Inspection

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

Storage

120-121

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

Taillight/Brakelight Lamp

Replacement

119

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

Throttle Cable Adjustment

101

. . . . . . . . .

Throttle Lever

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

Tire Inspection

110

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

Toe Alignment

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

Tool Kit

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

Torque Specifications

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

Trail Obstacles

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

Transmission Gear Selector

Operation

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

Transmission Lubrication

105-106

. . . . . .

Transmission Oil Changing

Procedure

105-106

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

Transporting

121

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

Traveling Downhill

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

Traveling Uphill

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

Troubleshooting

122

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

Turning Around On A Hill

. . . . . . . . . . .

Understanding Warnings

1-2

. . . . . . . . . . .

Vehicle Identification Numbers

. . . . . .

Warranty

124

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

Warranty

123

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

Wheel Installation

109

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

Wheel Removal

109

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

Summary of Contents for Universal ATV 2000

Page 1: ...TED IN THE U S A 2000 Universal ATV Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age Owner s Sa...

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

Page 3: ...YOUR SPORT Know all local state province riding laws Respect your vehicle Respect the environment and You will gain the respect of others We also advise you to strictly follow the recommended mainten...

Page 4: ...TV without wearing an approved helmet that fits properly You should also wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants Never consume alcohol or dr...

Page 5: ...de or to either side if pointed straight uphill Turn the ATV around and remount following the procedure described in this manual Always check for obstacles before operating in a new area Never attempt...

Page 6: ...bstantial safety hazard Polaris hereby informs you that the warranty on your ATV is terminated if any such equipment has been added to the ATV or any modifications have been made to the ATV which incr...

Page 7: ...toll free insurance telephone number is 1 800 473 0111 The chance to arrange travel through the Polaris Travel Center The toll free travel telephone number is 1 800 267 1915 The chance to apply to se...

Page 8: ...DENTIFICATION NUMBERS 34 CONTROL AND PARTS FUNCTIONS 35 54 STARTING THE ENGINE 55 VEHICLE BREAK IN PERIOD 56 57 RIDING GEAR 58 CARRYING LOADS 59 CARGO WEIGHT DISTRIBUTION 60 DAILY PRE RIDE INSPECTION...

Page 9: ...ronment SAFETY TRAINING When you purchased this vehicle your dealer presented a hands on safety training course covering all aspects of ATV safety In addition you were provided with cer tain printed m...

Page 10: ...hich could result in serious injury or death CAUTION Indicates a potential hazard which may result in minor personal inju ry or damage to the ATV NOTE The word NOTE in this manual will alert you to ke...

Page 11: ...your protection Read and follow the instructions on each decal carefully In the event any decal becomes il legible or comes off contact your Polaris dealer for a replacement Any safety de cal needing...

Page 12: ...4 SAFETY WARNING AND OPERATION DECALS 1 7077919 E1997...

Page 13: ...5 SAFETY WARNING AND OPERATION DECALS 2...

Page 14: ...ult When backing up proceed slowly and apply hand brakes carefully aggressive braking may result in flipover Avoid backing downhill Avoid turning at sharp angles in reverse USE OVERRIDE FOR REVERSE SP...

Page 15: ...7 SAFETY WARNING AND OPERATION DECALS 4 7 6 7 3 5...

Page 16: ...m tow hooks or hitch 7074954 7 Found on models with no racks Found on models with racks 4 5 IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL LOSS OF CONTROL CAN RESULT IN SEVERE INJURY...

Page 17: ...80 lbs on the rear rack ALL LOADS MUST BE SECURED BEFORE MOVING VEHICLE Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARR...

Page 18: ...Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW ON THE RACK AS POSSIBLE Carrying loads high on the rack rais...

Page 19: ...WILL SEVERELY DAMAGE THE ENGINE DCLEAN AIR FILTER OFTEN MORE FRE QUENT CLEANING REQUIRED IN DUSTY CONDITIONS DLiutilisation de ce v hicule sous li l ment filtre endommage s v rement le moteur DNettoy...

Page 20: ...D UNDER BELT 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...

Page 21: ...Manual Factory setting 40 to 80 F at 0 3000 feet 5 to 26 C at 0 900 meters 7073761 TRAILER MAX WEIGHT 850 LBS HITCH MAX VERTICAL WEIGHT 30 LBS POIDS MAX DE REMORQUE 386 KG POIDS MAX VERTICAL D ATTACH...

Page 22: ...adjustment and fluidlevel includesauxil iary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop...

Page 23: ...ed in the course and the operating tech niques 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 POTENTI...

Page 24: ...Greatly reduces your ability to balance and control this ATV Could cause an accident resulting in harmto youand or yourpassenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to al...

Page 25: ...WHAT CAN 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 A...

Page 26: ...ic streets 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...

Page 27: ...our chances of a se vere head injury or death in the event of an accident Operating without eye protection can result in an accident and in creases your chances of a severe injury in the event of an a...

Page 28: ...and perception 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 HAPP...

Page 29: ...G POTENTIAL 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...

Page 30: ...enance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during op eration WHAT CAN HAPPEN Removing even one hand or foot...

Page 31: ...WHAT 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 c...

Page 32: ...HAPPEN 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 unt...

Page 33: ...tice turning at 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...

Page 34: ...s described in the Owner s Manual See pages 65 through 68 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weigh...

Page 35: ...for going down hills as described in the Owner s Manual See page 67 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any h...

Page 36: ...nd on any hill until you have mas tered the turning technique as described in the Owner s Manual on level ground See page 68 Be very careful when turning on any hill Avoid crossing the side of a steep...

Page 37: ...ght uphill 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...

Page 38: ...g or sliding WHAT CAN HAPPEN You may lose control of the ATV You may also regain traction unexpectedly which may cause the ATV to overturn HOW TO AVOID THE HAZARD On slippery surfaces such as ice go s...

Page 39: ...than that specified in your Owner s Manual See page 69 Remember that wet brakes may have reduced stopping ability Test your brakes after leaving water If necessary apply them several times to let fric...

Page 40: ...tire pressure 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...

Page 41: ...ways follow the instructions in the Owner s Manual for carrying car go or pulling a trailer See pages 59 and 60 After a rollover or an accident have a qualified service dealer check the complete machi...

Page 42: ...ey and store 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...

Page 43: ...f position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other emergency NOTE Both the main switch and the emergency engine stop switch shut...

Page 44: ...with individual models and not every model is equipped with all the lights The informa tion in your Owner s Manual Supplement and in the following box willhelp youiden tify the lights on your machine...

Page 45: ...o display each mode press the button on the face of the speedometer once to toggle through the functions Each function will be displayed as follows Miles 00000 0 M Trip Miles 000 0 M Hours 00000 0 H T...

Page 46: ...rect choke and throttle settings during starting WARNING The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not at te...

Page 47: ...e from the air This causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of serious injury The front and rear brakes are applied by squeezin...

Page 48: ...g brake may relax when left on for a long period of time This could cause an accident Do not leave the vehicle on a hill depending on the parking brake for more than five minutes Always block the down...

Page 49: ...t aggres sively apply the auxiliary brake when going forward or the rear wheels may skid and slide sideways causing loss of control If the rear wheels slide reduce brake pedal pressure to brake the re...

Page 50: ...n heavy pulling situations to extend belt life To change gears stop the vehicle and with the engine idling move the lever to the desired gear Do not attempt to shift gears with engine speed above idle...

Page 51: ...ly disengage NOTE The override switch also allows ac tivation of Demand 4 Drive AWD in reverse if Demand 4 Drive switch is on There is no limit to the length of time the vehicle may remain in Demand 4...

Page 52: ...death If the hubs remain engaged after following these instructions return the ATV to your dealer for service PVT System WARNING The PVT system rotates at high speeds creating large amounts of force...

Page 53: ...tracting cooled coolant is drawn back up from the tank past the pres sure cap and into the radiator NOTE Some coolant level drop on new machines is normal as the sys tem is purging itself of trapped a...

Page 54: ...e front cov er by placing your fingers under the front of the cover and pulling upward NOTE Use of a non standard pres sure cap will not allow the recovery system to function properly If the cap shoul...

Page 55: ...quarts 1 9 l CAUTION To avoid serious engine damage always top off the oil level when refueling CAUTION On models with a twocycle engine use onlyPolaris injectionoil Never substitute or mix oil brands...

Page 56: ...enti lated area DDo not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored DDo not over fill the tank Do not fill the tank neck DIf you g...

Page 57: ...econds 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 angle and...

Page 58: ...screen torquing to 14 17 ft lbs Reattach oil line If banjo fitting D is used torque to 14 17 ft lbs If hose clamp E is used tighten securely 9 Place shop towels beneath oil filter Using an oil filter...

Page 59: ...and let it idle for one to two minutes Stop engine and inspect for leaks 18 Re check oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 19 Dispose...

Page 60: ...engine cleanli ness With new generation lubricity technology they excel in meeting the lubrica tion demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid c...

Page 61: ...ible by allowing compression to leak at cranking speeds The decompressor senses when the engine is spinning fast enough to start and re stores compression for starting 1 Be certain your vehicle is on...

Page 62: ...coil housing if the starter handle is disengaged from the rope guide when under water After travelling in wet areas the recoil housing and starter should always be drained completely by removing the r...

Page 63: ...gine does not start release starter but ton and wait five seconds then press starter button for another five seconds Repeat this procedure until engine starts NOTE Do not press the throttle while star...

Page 64: ...h is open and will give you room to famil iarize yourself with vehicle operation and handling 4 Vary the throttle positions CAUTION Do not operate at full throttle or high speeds for extended periods...

Page 65: ...ded or leaded fuel which has a minimum pump oc tane number of 87 R M 2 2 Check oil reservoir level indi cated on dipstick Add oil if necessary 3 Drive slowly at first Select an area which is open and...

Page 66: ...National 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 hel met face shield of...

Page 67: ...m vertical hitch weight 30 lbs 14 kg Select models may tow up to 1250 568 kg on level ground only Refer to your Owner s Manual Supplement to determine your machine s capabilities IMPORTANT Know your m...

Page 68: ...ds can create unstable operating conditions which could result in loss of control of the vehicle LOADS MUST BE CARRIED AS LOW ON THE RACKS AS POSSIBLE Car rying loads high on the racks raises the cent...

Page 69: ...adjustment and fluidlevel includesauxil iary brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all indicator lights and switches 6 Engine stop...

Page 70: ...ermine 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 and all trans...

Page 71: ...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 alters the balance of t...

Page 72: ...d and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engaged can assist in controlling the vehicle in slippery areas CAUTION Never engage Demand Drive while wheels are...

Page 73: ...g 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV WARNING Braking and handling are greatly affected whenever operating in hilly ter rain Loss of v...

Page 74: ...d the hill while keep ing your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn the front wheel downhill if possible or dismoun...

Page 75: ...e rear 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 W...

Page 76: ...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 slightly down ward 6...

Page 77: ...e 4 After crossing dry the brakes by applying light pressure to the lever until braking action is normal CAUTION Should your ATV become immersed it will be necessary to take it to your dealer as soon...

Page 78: ...antly alert for hazards such as logs rocks and low hanging branches WARNING Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obst...

Page 79: ...th caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Only open the throttle enough to maintain a de sired speed Opening the throttle more than required may ca...

Page 80: ...the transmission in gear 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 5 Shut off fu...

Page 81: ...da and one cup water Rinse well with tap water and dry off with clean rags Coat the terminals with dielectric grease or petro leum jelly Do not allow cleaning solution or tap water to enter the batter...

Page 82: ...first black negative cable last 1 Set the battery in its holder 2 Install the battery vent tube It must be free from obstructions and securely installed If not battery gases could accumulate and cause...

Page 83: ...BELOW 1 Removal or alteration or the puncturing of the muffler or any engine component which conducts removal of engine exhaust gases 2 Removal or alteration or the puncturing of any part of the engi...

Page 84: ...muffler back the machine onto an incline so the rear of the machine is one foot higher than the front Set the parking brake and block the wheels Make sure the machine is in neutral and repeat steps 2...

Page 85: ...area when purging the spark arrestor DWear eye protection DDo not stand behind or in front of the vehicle while purging the carbon from the spark arrestor DNever run the engine in an enclosed area The...

Page 86: ...k plug wrench and handle Dspanner wrench for adjusting rear shock spring preload selected models NOTE Other tools are also necessary to perform maintenance work They are called out later in this manua...

Page 87: ...evere use such as dirty or wet conditions L Emission Control System Service California 4 Cycle NOTE Some 4 Cycle models may have an additional California only emissions warranty Please refer to your o...

Page 88: ...rs 6 months Inspect adjust lubricate replace if nec essary pre ride inspection item L Choke Enricher Cable 50 hrs 6 months Inspect adjust lubricate replace if nec essary Coolant strength pressure test...

Page 89: ...every two years J Injector Oil Filter 2 Cycle 100 hrs Annually Replace J Shift selector box H L R 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change every two ye...

Page 90: ...level surface Change annually or at 100 hours 6 Front Prop Shaft U joints Grease Locate Fittings and Grease Every 3 months or 50 hours 7 Front Prop shaft Yoke Grease Locate fittings and grease 3 pump...

Page 91: ...nthly or at 20 hours 18 Upper Control Arms Grease Locate fittings and grease Semi annually 19 Lower Control Arms Grease Locate fittings and grease Semi annually 20 Rear Wheel Hub Bearing Car rier Grea...

Page 92: ...ations Operating Range Full 4 Transmission dipstick 6 Front Prop Shaft U Joint 10 Axle Cardan Front Drive AWD Models 7 Propshaft Yoke Fill plug 5 Front Gear Case 14 Counterbalance Dipstick 4 Transmiss...

Page 93: ...85 MAINTENANCE Lubrication Recommendations 15 Steering Post Bushings 11 Ball Joint 13 Front A Arm Pivot Shaft Lower Upper 9 4 O clock position 9 Demand 4 Hubs 4x4 only...

Page 94: ...ubrication Recommendations 17 Swing Arm Bushings 16 Rear Axle Bearing 18 Upper Control Arm 20 Rear Wheel Hub Bearing Carrier 21 Rear Anti Roll Bar 19 Lower Control Arm INDEPENDENT REAR SUSPENSION 19 L...

Page 95: ...CE 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 50 Hrs 75...

Page 96: ...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 equal gap a...

Page 97: ...el Nuts 50 Ft Lbs Front Spindle Nut s Dealer Performed Service 4x4 Front Wheel Nuts 15 Ft Lbs 4x4 Chain Drive Rear Axle Nut s 80 Ft Lbs Rear Wheel Nuts 50 Ft Lbs Front Spindle Nut s Dealer Performed S...

Page 98: ...ng Adjustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension Rear Spring Adjustment Cam Rear Spring Adjustment Cam...

Page 99: ...hind the fuel tank With a quick and firm motion push down on the side panel to disengage the top rear two tabs Then pull up on side panel to disengage front upper and lower tab 3 To reinstall side pan...

Page 100: ...lace if necessary Install filter into airbox Be sure filter element seats securely 8 Check cover gasket and replace if required Be sure cover is seated properly and wing nuts are finger tightened secu...

Page 101: ...bsorbant cloth 6 Reinstall the yellow foam boot and gray collar onto the air filter box 7 Reinstall the primary air filter box removed in step 2 NOTE There will be some resistance Be sure the black ru...

Page 102: ...p and remove filter 4 Remove fabric type pre filter from main filter Wash pre filter in soapy water and dry it 5 Reinstall pre filter over main filter Replace main filter as required 6 Reinstall filte...

Page 103: ...lamp or fil ter damage may oc cur CAUTION Operation of your ATV without a breather filter can cause engine dam age Breather Filter and Hose Sportsman 500 Magnum 500 Scrambler 500 1 Remove the clamps a...

Page 104: ...used as an indicator of whether the handlebars are straight The frog should always point straight back from the steering post 2 Place stands in front of the machine perpendicular to the rear tires 3 T...

Page 105: ...ndicated and the diaphragm should be replaced Always fill the reservoir as indicated whenever the cover is loos ened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid PN 28...

Page 106: ...he thickness of a dime DInspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to be used as a backup for the main...

Page 107: ...ssure on the throttle lever until all freeplay is re moved from throttle cable to the point where the carb slide is just starting to rise 4 Lift boot up off adjuster sleeve Remove the oil pump cover L...

Page 108: ...of its stop The pump stop keeps the pump arm from rotating any farther down than the idle position so no visual alignment of marks is nec essary Tighten the locknut Oil Pump Bleeding Procedure 1 Fill...

Page 109: ...fouling and very poor engine performance If there is too much choke cable slack resulting in excessive toggle free play the engine will be hard starting when cold and the half on choke position used...

Page 110: ...ed from 1 2 to 1 turn by turning the screw clockwise DDuring hot weather and or high altitude operation the air screw can be ad justed for smooth operation by approximately 2 turns counterclockwise Ch...

Page 111: ...uretor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turn ing the screw out counterclock wise will lower RPM Throttle Cable Free Play Adjustm...

Page 112: ...ip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes are excessive oil use of non recommended injecti...

Page 113: ...r hole The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871478 Transmission Oil Changing Procedure 1 Remove propshaft shield from the right side of the veh...

Page 114: ...plug dipstick and check the lubricant level Lubricant should be kept at the full mark on the dipstick The correct transmission lubricant to use is Polaris Premium Synthetic Gearcase Lubricant PN 2871...

Page 115: ...ar Lube to the bottom thread on the fill hole 5 Reinstall filler plug 6 Check for leaks Rear Gearcase Lubrication With the ATV on a level surface remove fill plug and visually inspect thelubricant lev...

Page 116: ...seat and locate dipstick 2 Remove dipstick Oil level is shown on dipstick 3 Add SAE 10W30 oilwith atransmis sion fluid funnel until oil is at the proper level on the dipstick If overfilled excess oil...

Page 117: ...Installation 1 With the transmission in gear and the parking brake locked place the wheel in the correct position on the wheel hub Be sure the valve stem is toward the out side and rotation arrows on...

Page 118: ...type tires may affect ATV handling Tire Tread Depth Always replace tires when tread depth is worn to 1 8 3 cm or less Please refer to your Owner s Manual Supplement for tire specifications WARNING Op...

Page 119: ...wash the chain with a high pressure washer or gasoline Dam age to the O rings will result causing premature wear and drive chain failure Always inspect the drive chain prior to operating the vehicle...

Page 120: ...ds adjustment usethe followingproce dure Adjustment Procedure 1 Loosen chain guide 2 Loosen two eccentric locking bolts 3 Loosen caliper mount bolts 4 Insert a pin punch through the sprocket hub and i...

Page 121: ...wise and remove bulb 3 Install bulb into headlight housing and rotate clockwise firmly NOTE Bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector High Beam...

Page 122: ...7 6 m from a wall 2 Measure the dis tance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine and turn on headlight 4 Observe headlight aim...

Page 123: ...by the re moval of the seat 5 Disengage the tabs at the front of the upper panel where they snap into the lower panel surrounding the headlight assembly Alsodisengage the tabs on the upper panel which...

Page 124: ...m Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the four screws at the outer corners of the lamp housing 1 Place the vehicle on a level surface with the he...

Page 125: ...and reassemble pod Make sure tab on lamp locks into place in housing High Beam Headlight Adjustment The headlight beam can be adjusted to any position desired by turning the adjust ing knob located on...

Page 126: ...od 3 Lift pod cover up Disconnect speedome ter harnesses from speedometer Un plug indicator light harness and remove pod cover 4 Unplug headlamp from wiring harness 5 Remove O Ring from headlight pivo...

Page 127: ...ator Lamp Replacement Style I 1 With a small flat screwdriver gently pry loose the indicator light cover 2 Using a small flexible tube such as an oil delivery hose grasp the burned out lamp and remove...

Page 128: ...contact your a Po laris dealer for free replacement Waxing Your ATV can be waxed with any quality brand automotive paste wax Avoid the use of harsh cleaners since they can scratch the body finish CAU...

Page 129: ...mixture becomes overly rich An engine loses approxi mately 3 of its power for each 1000 foot 304 8 m increase inelevation Although this power cannot be regained changes to the carburetor and drive sys...

Page 130: ...Spark Plug Fuel Valve Off Drain System No Spark to Spark Plug Contact Your Dealer Clogged Fuel Valve or filter ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse of C...

Page 131: ...nty Registration Form will be the warranty entitlement If you have not signed the original registration and re ceived the customer copy please contact your dealer immediately NO WAR RANTY COVERAGE WIL...

Page 132: ...PERIOD POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRAN TIES NOT STATED IN THIS WARRANTY Some states do not allow limitations on how long an implied warranty lasts so the above limitation may not apply to...

Page 133: ...Procedure 107 Handlebar Adjustment 88 Headlight Adjustment 113 117 Headlight Lamp Replacement 113 117 Indicator Lamp Replacement 119 Indicator Lights 36 Light Switches 36 Load Capacity 59 Lubricant 2c...

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Summary of Contents for Universal ATV 2000

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Polaris Universal ATV 2000, Owner'S Safety And Maintenance Manual, Page: 133 / 133

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Summary of Contents for Universal ATV 2000

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