Polaris UTV 2x4 Series 11 Owner'S Manual Download Page 56

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MAINTENANCE AND LUBRICATION

Periodic Maintenance Schedule

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication

intervals of important components are explained in the following

schedule.
Maintenance intervals are based upon average operating conditions.

Vehicles subjected to severe use, such as operation in wet or dusty

areas, should be inspected and serviced more frequently. If you’re not

familiar with safe service and adjustment procedures, have a qualified

dealer perform these operations.
Inspect, clean, lubricate, adjust or replace parts as necessary. When

inspection reveals the need for replacement parts, always use genuine

Polaris parts available from your Polaris dealer.

Maintenance Chart Key

Perform these operations more often under severe use, such as in

dirty or wet conditions, to purge water or dirt contamination from

grease fittings and other critical components.

Emission Control System Service (California - 4-Cycle)

NOTE:

Some 4-Cycle models may have an additional California

-only emissions warranty. Please refer to your owner’s manual

supplement for model specific information.

Dealer service item.

Summary of Contents for UTV 2x4 Series 11

Page 1: ......

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

Page 3: ...1 ...

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

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

Page 6: ... are essential to the recovery and identification of your vehicle Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys If both keys are lost the ignition switch must be replaced See your Polaris dealer NOTE Record your vehicle s ID numbers and key number 3 in the spaces provided 1 31XX 3 2 Frame VIN behind le...

Page 7: ...UMBERS 4 TABLE OF CONTENTS 5 SAFETY 7 FEATURES 25 FEATURES AND CONTROLS 30 CONTROLS 31 OPERATION 34 NOISE EMISSION CONTROL SYSTEM 53 MAINTENANCE AND LUBRICATION 54 SPECIFICATIONS 96 POLARIS RECOMMENDED PRODUCTS 98 TROUBLESHOOTING 99 WARRANTY 102 INDEX 104 ...

Page 8: ...6 NOTES ...

Page 9: ...cerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals WARNING Failure to follow the warnings contained in this manual can result in severe inju...

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

Page 11: ... driving this vehicle in an aggressive manner Eye protection is recommended at all times S Never consume alcohol or drugs before or while operating this ve hicle S Never operate at excessive speeds Always travel at a speed proper for the terrain visibility and operating conditions and your experi ence S Never attempt wheelies jumps or other stunts S Always inspect your vehicle each time you use it...

Page 12: ...el downhill at high speed Avoid going downhill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill where pos sible S Always check for obstacles before operating in a new area Never attempt to operate over large obstacles such as rocks or fallen trees Always follow the proper procedures outlined in this manual when operating over obstacles S Always be...

Page 13: ...n case of a sudden stop or collision S Always keep arms and legs inside the cab frame while the vehicle is in motion S Always apply the parking brake before getting out of the vehicle See page 33 S Always activate the foot pedal brake before releasing the park brake S Always turn off the engine before refueling Make sure the refueling area is well ventilated and free of any source of flame or spar...

Page 14: ... accessories including but not limited to mowers blades tires sprayers or large racks may change the handling characteristics of the vehicle Use only Polaris approved accessories and familiarize yourself with their function and effect on the vehicle WARNING Make sure your Polaris UTV is in excellent operating condition at all times We strongly recommend that the operator check all safety component...

Page 15: ...ill If you lose all forward speed Apply the brakes Lock the parking brake after when fully stopped If you begin rolling backwards Never apply engine power Apply the brake gradually When fully stopped lock parking brake In the event of an accident have a qualified service dealer check the complete vehicle for possible damage including but not limited to brakes throttle and steering WARNING ...

Page 16: ...the vehicle on pavement If you must operate on a paved surface travel slowly and do not make sudden turns or stops WARNING POTENTIAL HAZARD Operating this vehicle without proper instruction WHAT CAN HAPPEN Loss of control accident HOW TO AVOID THE HAZARD The risk of an accident is greatly increased if the operator does not know how to operate the vehicle properly in different situations and on dif...

Page 17: ...s WARNING POTENTIAL HAZARD Operating this vehicle after consuming alcohol or drugs WHAT CAN HAPPEN Could seriously affect your judgment Could cause you to react more slowly Could affect your balance and perception Could result in an accident HOW TO AVOID THE HAZARD Driving a UTV requires your full attention DO NOT drink alcohol or use drugs or medications before or while driving They will reduce y...

Page 18: ...e WARNING POTENTIAL HAZARD Attempting jumps and other stunts WHAT CAN HAPPEN Loss of control accident and or vehicle overturn HOW TO AVOID THE HAZARD Never attempt jumps and other stunts Avoid exhibition driving WARNING POTENTIAL HAZARD Operating on frozen bodies of water WHAT CAN HAPPEN Severe injury or death can result if the UTV and or the operator fall through the ice HOW TO AVOID THE HAZARD N...

Page 19: ...e inspection and maintenance procedures and schedules described in the Owner s Manual POTENTIAL HAZARD Failure to use extra caution when operating this vehicle on unfamiliar terrain WHAT CAN HAPPEN Loss of control vehicle overturn HOW TO AVOID THE HAZARD Travel slowly and use extra caution when operating on unfamiliar terrain Always be alert to changing terrain conditions when operating the vehicl...

Page 20: ...e as described on the decal and in the Owner s Manual See page 97 WARNING POTENTIAL HAZARD Failure to follow the minimum age recommendations for this vehicle WHAT CAN HAPPEN Serious injury or death the child or others HOW TO AVOID THE HAZARD Only persons with a valid driver s license should operate a Polaris UTV Even though a child may be within the age group for which some vehicles are recommende...

Page 21: ...ted to brakes throttle and steering systems CAUTION Always keep combustible materials away from the exhaust system Exposure to the hot components could result in a fire 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 WARNING ...

Page 22: ...ill increase your risk of losing control Loads should be centered and carried as low as possible in box For stability on rough or hilly terrain reduce speed and cargo Be careful if load extends over the side of the box Read Owner s Manual for more detailed loading information 7079424 S Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed S...

Page 23: ...uent cleaning required in dusty conditions DOperation of this vehicle without engine breather filter s can cause engine damage Consult owner s manual for details DSpecific carburetor jetting and adjust ments are required depending on tem perature and altitude See your Own er s Manual Factory setting 40_ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters 7079902 Location 3 ...

Page 24: ...E IS A GENERAL PURPOSE OFF ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS PRINTED IN U S A 7078472 CE VÉHICULE USAGE GENERAL VEHICULE UTILIT AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DES TINE A ETRE UTILISE SUR LES CHEMINS PUBLICS Remove flammable containers from box before refueling Location 4 under hood Location 5 inside front of box 4 5 WARNING WARNING WARNING Maximum 2x4 Box ...

Page 25: ... ALWAYS S Avoid paved surfaces which may adversely affect handling and control S Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and rough terrain and in turns S Wear eye protection REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent flipover avoid sharp turns The park emergency brake lever will supply increased braking but should be used as...

Page 26: ...a Do not smoke or allow open flames or sparks in or near the refueling area or where gasoline is stored Do not over fill 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 change clothing Never start the engine or let it run in an enclosed area Gasoline powered engine exhaust fumes are poisonous and can cause loss of consc...

Page 27: ...25 FEATURES Component Locations 1 Cab Frame 2 Cab Frame Hand Hold 3 Console 4 Steering Wheel 5 Seat 6 Cargo Box 7 Seat Belts 8 Fuel Tank Cap Fuel Gauge 9 Battery under driver s seat 1 4 7 5 6 2 3 8 9 ...

Page 28: ...26 FEATURES Component Locations 10 Headlights 11 Radiator 12 Front Bumper Brush Guard 13 Hood Hold Down Strap 12 11 10 13 ...

Page 29: ... Tank 15 Battery under driver s seat 16 Tail Lights 17 Tail Gate 18 Tailgate Latch Release 19 Air Box under cargo box 20 Muffler Spark Arrester 21 Rear Caliper 22 Trailer Hitch Receiver 23 Engine Oil Plug 16 16 22 20 18 15 23 14 21 21 19 17 ...

Page 30: ...uipped with a receiver hitch bracket for a trailer hitch Trailer towing equipment is not supplied with this vehicle To avoid injury and property damage observe the precautions on page 49 Fuel Cap Fuel Gauge The fuel tank filler cap 1 is located on the right hand side of the vehicle near the passenger seat It has a built in fuel gauge that indicates the amount of fuel remaining in the tank When the...

Page 31: ...ross your lap as low on your hips as possible taking care that the belt is not twisted 2 Push the latch plate into the buckle until it clicks 3 Release the strap it will self tighten NOTE The center belt must be tightened manually by pulling on the strap To unfasten press the square red button in the buckle s center WARNING Falling from a moving vehicle could result in serious injury or death Alwa...

Page 32: ...ator Lights 4 Light Switch 5 AWD Switch if equipped 6 Cargo Box Dump Switch 7 Hour Meter 8 Glove Box with Lid 9 12V Accessory Plug 10 Storage Tray 11 Choke Knob 12 Ignition Switch 13 Shift Lever 14 Differential Lock Lever 2x4 and 4x4 12 11 7 3 9 14 13 8 1 2 4 5 2 10 6 ...

Page 33: ...the vehicle is moving Always place the transmission in gear with the parking brake locked whenever the vehicle is left unattended Maintaining shift linkage adjustment is important to assure proper transmission function See your dealer if you experience any shifting problems NOTE This vehicle is equipped with a reverse alarm The alarm is activated when the transmission is shifted to reverse 1 H L N...

Page 34: ... to 2WD Under some conditions it s possible for the AWD to remain engaged See page 51 for manual disengagement instructions Cargo Box Dump Switch The cargo box can be dumped or lowered by holding the dump switch up to dump or down to return to level OFF ON START Engine off All electrical circuits are off except Acc 12V Electrical circuits are on Electrical equipment can be used Electric starter is...

Page 35: ...ing while parked To apply the parking brake push down on the pedal with your foot To release pull the release handle 4 which is located on the lower console Spring pressure helps return the lever to the released position Make sure the parking brake lever is functioning properly before each operation Differential Lock The rear axle on 2x4 and 4x4 models is equipped with a lockable differential that...

Page 36: ... safe operating range 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 35 6 Pull only light loads 7 During the break in period change both the oil a...

Page 37: ...indicator lights and switches 6 Engine ignition switch check for proper function 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Air cleaner element check for dirt clean or replace 9 Steering check for free operation noting any unusual looseness in any area 10 Loose parts visually inspect vehicle for any damaged or loose nuts bolts or fast...

Page 38: ...throttle to aid in warm up until the engine idles smoothly Then push the choke all the way in Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death Never run an engine in an enclosed area WARNING Operating the vehicle immediately after starting could cause engine damage Allow the engine to warm up for several minutes before operat...

Page 39: ...tart intermittent use of the choke knob pulled half way out may be necessary 6 If the engine is over choked when warm depress the throttle lever fully while cranking to aid in starting 7 Release the throttle lever immediately after the engine starts NOTE If the engine does not start and all conditions are favorable change the spark plug Stopping the Engine 1 Release the throttle pedal completely a...

Page 40: ... re familiar with the controls NOTE When the throttle pedal is released completely and the engine speed drops near an idle the vehicle has no engine braking WARNING Failure to allow for increased braking distance when hauling cargo or towing a trailer may result in accident and injury Always slow down and allow additional braking distance when towing or hauling cargo ...

Page 41: ...he parking brake 5 Keeping both hands on the steering wheel slowly depress the throttle with your right foot and begin driving Vehicle speed is controlled by the amount of throttle opening and Polaris Variable Transmission PVT shifting is automatic 6 Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces NOTE Low is the primary gear for operating this vehicle High ge...

Page 42: ...he steering wheel in the direction of the skid 4 Drive with AWD engaged to assist in controlling the vehicle Severe damage to the drive train may occur if the AWD is engaged while the wheels are spinning Always allow the wheels to stop spinning before engaging AWD CAUTION WARNING Failure to exercise care when operating on slippery surfaces can result in loss of tire traction and cause loss of cont...

Page 43: ...re climbing a hill Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn and result in serious injury or death Avoid climbing steep hills 15_ maximum Use extreme caution when operating on hills and follow proper operating procedures outlined in the owner s manual Never climb hills with excessively slippery or loose surf...

Page 44: ...when possible When unavoidable exercise extreme caution Avoid operating on steep hills 15_ maximum WARNING Traveling downhill improperly could cause loss of control or vehicle overturn Always check the terrain carefully before descending a hill Never descend a hill at high speed Excessive speed may result in loss of vehicle control and lead to serious injury or death Always operate slowly when tra...

Page 45: ...rvices outlined in the Periodic Maintenance Schedule beginning on page 54 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings WARNING The large tires on your Polaris UTV may cause the vehicle to float in deep or fast flowing water which could result in loss of control and lead to serious injury or death Never cross deep or fast flowing water with ...

Page 46: ...errain you re traveling on Watch for hazards such as logs rocks and low hanging branches Severe injury or death can result if your vehicle suddenly comes in contact with a hidden obstacle Not all obstacles are immediately visible Reduce speed and travel with caution in unfamiliar terrain WARNING ...

Page 47: ...d backing downhill 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing WARNING Failure to use caution when operating in reverse can result in serious injury or death Before shifting into reverse always check for obstacles or people behind the vehicle and follow the reverse operation procedures outlined in this manual Always back slowly ...

Page 48: ...RNING A rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position instead Operating the vehicle while the parking brake is engaged could cause loss of control and result in serious injury or death Always disengage the p...

Page 49: ...Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when hauling cargo Always load the cargo box with the load as far forward as possible Always operate the vehicle with extreme care when hauling or towing loads Slow down and drive in low gear WARNING Driving with passenge...

Page 50: ...mp switch in the upward position to dump 4 Press and hold the cargo box dump switch in the downward position to return the box to a level position WARNING Operating the vehicle while the cargo box is raised could result in severe injury The rear tires will also catch the rear of a raised box damaging the vehicle and creating hazardous driving conditions Never operate this vehicle with the cargo bo...

Page 51: ...e WARNING Towing improperly can alter vehicle handling and may cause loss of control or brake instability which can result in serious injury or death Always follow these precautions when towing Never load more than 150 lbs 68 1 kg tongue weight on the towing bracket Do not operate the vehicle faster than 10 mph 16 km h when towing Towing a trailer increases braking distance Do not tow more than th...

Page 52: ... rolling vehicle can cause property damage and serious injury Always apply the parking brake after stopping the engine WARNING Gasoline is extremely flammable and can be explosive under certain conditions When parking inside a garage or other structure be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks including any appliance with pilot...

Page 53: ... will not release until the rear wheels regain traction Disengaging AWD Under certain conditions it may be possible for one or both hubs to remain engaged unnecessarily This condition causes increased steering effort and some vehicle speed restriction Take the following steps to disengage the AWD system 1 Stop the vehicle 2 Shift to reverse and back up a minimum of 10 feet 3 Stop completely 4 Shif...

Page 54: ...52 NOTES ...

Page 55: ...ED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED 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 engine air induction system 3 Replacement of any vehicle parts with parts not in compliance with federal regulations 4 Lack of proper maintenance USFS Approve...

Page 56: ...ce and adjustment procedures have a qualified dealer perform these operations Inspect clean lubricate adjust or replace parts as necessary When inspection reveals the need for replacement parts always use genuine Polaris parts available from your Polaris dealer Maintenance Chart Key Perform these operations more often under severe use such as in dirty or wet conditions to purge water or dirt conta...

Page 57: ...electric grease to connector when replaced Tail lamp Daily Check daily apply Polaris dielec tric grease to socket when re placed ROPS Daily Inspect for damage or wear See page 85 L Air Filter Main Ele ment Weekly Inspect replace if necessary Transmission Oil 25 hrs Check level change oil annually Battery 25 hrs Check terminals clean check fluid level More often under severe use such as dirty or we...

Page 58: ...l Filter 100 hrs Replace with oil change L Engine breather hose 100 hrs Inspect Carburetor Float Bowl 50 hrs Drain bowl periodically and prior to storage J Throttle Cable 50 hrs Inspect adjust lubricate replace if necessary L Choke Enricher Cable 50 hrs Inspect adjust lubricate replace if necessary Shift linkage 50 hrs Inspect adjust J Drive belt 50 hrs Inspect adjust replace if necessary J Steeri...

Page 59: ...mp and carbure tor Replace lines every two years Fuel Filter 100 hrs Replace annually Cooling System hoses 100 hrs Inspect Spark arrestor 100 hrs Clean out Front Gearcase Oil 100 hrs Check monthly change annually J Clutches drive and driven 100 hrs Inspect clean J Brake fluid 200 hrs Change every two years J Front wheel bearings 300 hrs Inspect replace if necessary L Idle Speed As required Adjust ...

Page 60: ...ours Main Gearcase Oil Transmission Premium Synthetic Gearcase Lube Maintain at the bottom of the fill plug threads See page 64 Check monthly Change annually Front Gearcase Oil Premium Drive Hub Fluid Maintain 3 4 19 mm below the bottom thread of the fill plug hole See page 65 Check monthly Change annually Middle Gearcase Oil Premium Gearcase Lube Maintain at the bottom of the fill plug threads Se...

Page 61: ...59 MAINTENANCE AND LUBRICATION Lubrication Recommendations 1 2 ...

Page 62: ...eration more power output and lower fuel consumption Although Polaris Premium 4 is the only oil recommended for use in this engine use of any API certified SH oil is allowable as long as it s 0W 40 Oil may need to be changed more frequently if Polaris Premium 4 is not used Follow the manufacturer s recommendations for ambient temperature operation CAUTION Mixing brands or using a non recommended o...

Page 63: ... and 30 F if most trips are slow speed and less than five miles Always change the oil filter when changing oil Oil Check The oil tank is located under the seat 1 Position the vehicle on a level surface 2 Start the engine and let it idle for 20 30 seconds 3 Stop the engine and remove the seat as described on page 29 4 Remove the dipstick 1 and wipe it dry with a clean cloth 5 Replace the dipstick a...

Page 64: ...g C on the bottom of the oil tank 7 Remove the screen fitting and clean the screen thoroughly 8 Apply Loctitet 565 Thread Sealant to the clean and oil free threads of the fitting NOTE See page 98 for the part numbers of Polaris recommended products 9 Reinstall the screen fitting and tighten to 14 ft lbs 19 Nm 10 Reinstall the oil hose on the fitting and reinstall the clamp 11 Place shop towels ben...

Page 65: ...ynthetic Oil 18 Place the gear selector in neutral and set the parking brake 19 Prime the oil pump using the procedure below Then stop the engine and inspect for leaks 20 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 21 Dispose of used filter and oil properly Oil Pump Priming Procedure This priming procedure must be performed w...

Page 66: ...ill plug hole Add Polaris Premium Synthetic Gearcase Lube if necessary See page 98 for the part numbers of Polaris recommended products 4 Reinstall the fill plug and torque to specification Oil Change 1 Remove the skid plate if necessary 2 Remove the fill plug 3 Remove the drain plug and drain the oil into a drain pan Dispose of used oil properly 4 Wipe the magnetic end of the drain plug clean to ...

Page 67: ...mbers of Polaris recommended products The front gearcase fill plug 1 is located on the right side of the front gearcase Oil Check 1 With the UTV on a level surface remove the fill plug and check the lubricant level Lubricant should be 3 4 19 mm below the bottom thread of the fill plug hole 2 Replace the fill plug and torque to specification Oil Change 1 Support the vehicle securely with a jack sta...

Page 68: ... of the gearcase Oil Check 1 With the UTV on a level surface remove the middle gearcase fill plug and check the lubricant level Lubricant should be even with the bottom thread of the fill plug hole 2 Reinstall the fill plug and torque to specification Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase and drain the oil into a drain pan Discard used oil prop...

Page 69: ... the fill plug and torque to specification Oil Change 1 Remove the fill plug 2 Remove the drain plug 2 from the bottom of the gearcase and drain the oil into a drain pan Discard used oil properly 3 Clean and reinstall the drain plug Torque to specification 4 Add Polaris Premium Gearcase Lube until it reaches the bottom thread of the fill plug hole 5 Reinstall the fill plug and torque to specificat...

Page 70: ...he tank past the pressure cap and into the radiator NOTE Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle Adding or Changing Coolant To ensure that the coolant maintains its ability to protect the engine the system be completely drained every two years and a f...

Page 71: ...t must be added often or if the overflow bottle runs completely dry there may be a leak in the system Have the cooling system inspected by your Polaris dealer Radiator Coolant Level 1 Lift the hood and slowly remove the radiator cap 1 2 View the coolant level through the 3 Using a funnel slowly add coolant if necessary NOTE This procedure is required only if the cooling system has been drained for...

Page 72: ... air flow can lead to overheating and consequent engine damage Coolant absorbs excessive heat from the engine and transfers it to the air at the radiator If the coolant level becomes low the engine overheats and may suffer damage Check the coolant level each day before operating the vehicle and replenish coolant if the level is low Change the coolant as outlined in the Periodic Maintenance Schedul...

Page 73: ... in this warning can result in severe injury or death Do not modify any component of the PVT system Doing so may reduce its strength so that a failure may occur at a high speed The PVT system has been precision balanced Any modification will cause the system to be out of balance creating vibration and additional loads on components The PVT system rotates at high speeds creating large amounts of fo...

Page 74: ...ectric start 6 Dry the spark plug and reinstall or install a new plug 7 Tighten the carburetor drain screw 8 Reconnect the fuel pump wires 9 Attempt to start the engine If necessary repeat the drying procedure 10 Take the vehicle to your dealer for service as soon as possible whether you succeed in starting it or not NOTE If water has been ingested into the PVT follow the procedure on page 71 for ...

Page 75: ...ould adhere tightly to the cover and seal all the way around 3 Remove the air filter 1 4 Do not attempt to clean the main element Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Inspect the air box for oil or water deposits If present drain them into a suitable container NOTE Service the air filter more frequently ...

Page 76: ...clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter with the arrow pointing toward the engine and secure the clamps Fuel Filter Your Polaris UTV is equipped with an in line fuel filter that should be replaced by your dealer after every 100 hours of operation Do not attempt to clean the fuel filter 1 2 Operation of the vehicle...

Page 77: ... plug or incorrect carburetion adjustments 2 Wet Fouled The wet fouled insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nose Generally the electrodes are not worn General causes of fouling are excessive oil use of non recommended injection oil improper use of the choke or incorrect carburetion adjustments Spark Plug Removal and Replacement 1 ...

Page 78: ...hot Exhaust system temperatures can reach 1000 F Allow components to cool sufficiently before proceeding Remove any combustible materials from the area Wear eye protection Do not stand behind or in front of the vehicle while purging Never run the engine in an enclosed area Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time Never go und...

Page 79: ... 4 If particles are still suspected to be in the muffler back the vehicle onto an incline so the rear of the vehicle is one foot higher than the front Set the parking brake and block the wheels Make sure the vehicle is in neutral and repeat steps 2 and 3 5 If particles are still suspected to be in the muffler drive the vehicle onto the incline so the front of the vehicle is one foot higher than th...

Page 80: ...play Inspection 1 Apply the parking brake 2 2 Put the gear shift lever in the neutral position 3 Start the engine and warm it up thoroughly 4 Measure the distance the throttle pedal moves before the engine begins to pick up speed Freeplay should be 1 16 to 1 8 inches WARNING Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or...

Page 81: ...able adjuster sleeve 2 Loosen the adjuster locknut 3 2 Turn the adjuster until 1 16 to 1 8 inch freeplay is achieved NOTE While adjusting freeplay you must flip the throttle lever back and forth 3 Tighten the locknut and slide the boots over the cable adjuster until they touch at the midpoint of adjuster 1 1 2 3 ...

Page 82: ...parking brake 2 Place the gear shift lever in the neutral position 3 Warm up the engine by running the vehicle approximately five minutes 4 Remove the the seat and locate the idle screw 1 5 Place the transmission in gear with the parking brake applied 6 Adjust the carburetor idle screw in or out until the desired idle RPM is reached Turn the screw in clockwise to raise RPM Turn the screw out count...

Page 83: ... the reservoir are unknown Inspection Procedure 1 Position the vehicle on level ground 2 Inspect the brake fluid by looking at the reservoir 1 under the hood The level should be between the upper MAX and lower MIN level lines 3 If the fluid level is lower than the lower level line add brake fluid to the upper MAX line 4 Apply the brake forcefully for a few seconds and check for fluid leakage aroun...

Page 84: ...th your foot 2 After 8 to 12 clicks of lever travel check the vehicle for movement The vehicle should not roll while parked If the vehicle moves adjustment is necessary Parking Brake Adjustment 1 Place the vehicle in neutral on a flat level surface 2 Carefully lift the rear of the vehicle off the ground and stabilize on jack stands 3 Loosen the locknut on the rear caliper adjustment bolt 4 Tighten...

Page 85: ...urn the steering wheel left and right 3 There should be 0 8 1 0 in 20 25 mm of free play 4 If there is excessive freeplay or strange noises or the steering feels rough or catchy have the steering system inspected by an authorized Polaris dealer Rear Spring Adjustment The rear shock absorber springs are adjusted by rotating the adjustment cam 1 either clockwise or counterclockwise to increase or de...

Page 86: ...at belt is adjustable and should be adjusted for both the operator and passenger before driving Although having the belt at 30 is typical for many people it will not accommodate all body sizes and shapes Make sure the seat belt is adjusted to the lowest possible lap position before riding 1 To adjust loosen the bolts 1 2 Reposition both the buckle and retractor Tighten bolts NOTE The center belt d...

Page 87: ...unting hardware that is of a grade lesser than specified S Any cracks in the structure structural members and or welds S Significant corrosion S Modifications unauthorized welds or holes S Missing or unreadable ROPS label S Applicable ROPS machine model not specified on the ROPS label S Machine GVW including attachments restrained payload fuel and operator in excess of the maximum weight specified...

Page 88: ...hardware Always inspect the ROPS immediately after any type of collision rollover or impact If any damage is evident remove the ROPS from service until it can be repaired or replaced When a ROPS is removed or installed mounting hardware must be examined for signs of over stressing Always replace damaged mounting hardware before placing the ROPS back in service All UTV operators and passengers must...

Page 89: ...taining Nut s 120 ft lbs Rear Wheel Nuts 35 ft lbs WARNING Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident which could result in serious injury or death Always replace tires when the tread depth measures 1 8 3 cm or less Improper tire inflation or the use of non standard size or type of tires may adversely affect vehicle handling whi...

Page 90: ...e parking brake locked place the wheel in 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 2 Attach the wheel nuts and washers and finger tighten 3 Carefully lower the vehicle to the ground 4 Torque the wheel nuts according to the specifications on page 87 Operating your UTV with improperly installed wh...

Page 91: ...forming this step 5 Adjust beam to desired position by turning adjustment screws 1 in headlight cover as follows Turn the right screw clockwise to adjust to the left Turn the left screw clockwise to adjust to the right Turn the bottom screw clockwise to adjust upward Brake Lights When the brake pedal is depressed the console brake light comes on Check the brake light before each ride 1 Turn the ig...

Page 92: ... 5 Grip the light with a needle nose plier and remove the light from the assembly 6 Install the new light and use a small flat head screwdriver to seat it into place 1 4 turn clockwise 7 Snap the assembly back into the console panel and reconnect the harness 8 Close the hood Tool Kit To help you perform routine maintenance a tool kit is provided with your vehicle Items included in the kit are S A ...

Page 93: ...e all zerk fittings immediately after washing Also run the vehicle to evaporate any water that may have entered the engine or exhaust system Storage If your vehicle is to be placed in extended or off season storage the following steps should be taken to preserve its condition 1 Perform all necessary repairs and thoroughly clean the vehicle 2 Remove the spark plug and pour approximately one ounce o...

Page 94: ...e sure the spark plug is tight 3 Fill the fuel tank with fuel 4 Check all the points listed in the Daily Pre Ride Inspection section beginning on page 35 NOTE Tightness of the bolts nuts and other fasteners should be checked by an authorized Polaris dealer 5 Lubricate as outlined in the Periodic Maintenance Schedule Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousn...

Page 95: ... or tap water into the battery Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote External Flush with water Internal Drink large quantities of water or milk Follow with milk of magnesia beaten egg or vegetable oil Call physician immediately Eyes Flush with water for 15 minutes and get prompt medical attention Batteri...

Page 96: ...3 Disconnect the black negative battery cable first 4 Disconnect the red positive battery cable next 5 Lift the battery out of the vehicle being careful not to tip it sideways and spill any electrolyte 1 Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When r...

Page 97: ...d tighten the red positive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE 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 Battery Storage When the vehicle is plac...

Page 98: ...117 x 25 4 cm 58 x 46 x 10 in 147 x 117 x 25 4 cm 58 x 46 x 10 in 147 x 117 x 25 4 cm Min Turning Radius 132 in 335 3 cm 132 in 335 3 cm 186 in 472 4 cm Engine Oil Capacity 2 qts 2 1 l 2 qts 2 1 l 2 qts 2 1 l Coolant Capacity 2 25 qts 2 4 l 2 25 qts 2 4 l 2 25 qts 2 4 l Engine 4 valve 4 stroke single cylinder with counter balance 4 valve 4 stroke single cylinder with counter balance 4 valve 4 stro...

Page 99: ...hydraulic Foot Activated 4 wheel hydraulic Foot Activated 4 wheel hydraulic wheel hydraulic disc wheel hydraulic disc wheel hydraulic disc Front Hydraulic disc floating caliper Hydraulic disc floating caliper Hydraulic disc floating caliper Rear Hydraulic disc floating caliper with mechanical parking brake Hydraulic disc floating caliper with mechanical parking brake Hydraulic disc floating calipe...

Page 100: ...Pump for Gearcase Oil 2871654 Premium Drive Hub Fluid 8 oz 2872277 Premium Drive Hub Fluid 2 5 gal 2871653 Angle Drive Fluid 8 oz Grease Specialized Lubricants 2871322 Premium All Season Grease 3 oz cartridge 2871423 Premium All Season Grease 14 oz cartridge 2871460 Starter Drive Grease 2871515 Premium U Joint Lube 3 oz 2871551 Premium U Joint Lube 14 oz 2871312 Grease Gun Kit 2871329 Dielectric G...

Page 101: ... in fuel Drain the fuel system and refuel Fuel valve is turned off Turn the fuel valve on Old or non recommended fuel Replace with new fuel Fouled or defective spark plug s Inspect plug s replace if necessary No spark to spark plug Inspect plug s verify stop switch is on Crankcase filled with water or fuel Immediately see your Polaris dealer Overuse of choke Inspect clean and or replace spark plug...

Page 102: ...se ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12 5 VDC Kinked or plugged fuel vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction See y...

Page 103: ...es See your Polaris dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Low battery voltage Recharge battery to 12 5 VDC Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your Polaris dealer Electronic throttle control malfunction...

Page 104: ...ediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS Initial dealer preparation and set up of your vehicle is very important in ensuring trouble free operation Purchasing a machine in the crate or without proper dealer set up will void your warranty coverage WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty ...

Page 105: ...CLAIMS ALL EXPRESS WARRANTIES 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 you if inconsistent with controlling state law HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service you must take it to a Polaris Servicing Dealer When requesting warranty service you must present your copy...

Page 106: ... Driving Through Water 43 Driving Uphill 41 Dumping the Cargo Box 48 E Engine Idle RPM Adjustment 80 Engine Oil 60 63 Equipment Modifications 12 F FEATURES 25 29 FEATURES AND CONTROLS 30 F Filter Systems 73 74 Front Gearcase 65 Fuel Cap 28 Fuel Filter 74 Fuel Gauge 28 Fuel Safety 24 G Gear Selector 31 Gearcase Specification Chart 67 Gearcases 64 67 H Hauling Cargo 47 49 Headlight Beam Adjustment 8...

Page 107: ... 96 97 Starting a Cold Engine 36 Starting a Warm Engine 37 Starting the Engine 36 37 Steering Wheel Inspection 83 Stopping the Engine 37 Storage 91 Switches 32 T TABLE OF CONTENTS 5 Throttle Freeplay 78 Throttle Pedal 33 Throttle System 78 79 Tire Tread Depth 87 Tires 87 88 Tool Kit 90 Torque Specifications 87 Towing Capacities 49 Towing Loads 49 Trailer Hitch Bracket 28 Transmission 64 TROUBLESHO...

Page 108: ...Part No 9918186 Rev 02 PRINTED IN THE USA ...

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Polaris UTV 2x4 Series 11, Owner'S Manual

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