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Polaris UTV Series 10 2x4, Owner'S Manual

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Polaris UTV Series 10 2x4 Owner'S Manual Download Page 101

99

TROUBLESHOOTING

Procedures

The following information is provided to help you identify probable

causes for questions you may have about the operation of your vehicle.

See your Polaris dealer with any additional questions you may have.

Disengaging AWD System

Under certain conditions, it may be possible for the AWD system to

remain engaged. 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 into reverse and back up a minimum of 10 feet.
3. Come to a complete stop.

4. Shift into forward and drive.
If the hubs remain engaged after following these instructions return the

vehicle to your dealer for service.

Summary of Contents for UTV Series 10 2x4

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: ...2 NOTES ...

Page 5: ...d enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance but major repairs are covered in the Polaris Service Manual and should be performed by a Factory Certified Master Service Dealer MSD Technician Your Polaris UTV dealer knows your vehicle best and is interested in your complete satisfaction Return to your dealership for all of your service needs du...

Page 6: ... unless the guest has read this manual and all product labels n To reduce tipover risk be especially careful when encountering obstacles and slopes and when braking on hills or during turns n Always fasten your seat belts securely around you n This vehicle is for off road use only Never operate on public roads Always avoid paved surfaces n Helmets are recommended whenever driving this vehicle in a...

Page 7: ...f a hill at high speed n Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills Check the terrain carefully before descending a hill Never travel 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 possible n Always follow proper procedures for cros...

Page 8: ...exceed the stated load capacity for this vehicle Cargo should be properly distributed and securely attached Reduce speed and follow the instructions in this manual for hauling cargo or pulling a trailer Allow a greater distance for braking n Always wear the seat belts when operating this vehicle Seat belts reduce the severity of injury in case of a sudden stop or collision n Always keep arms and l...

Page 9: ...ated if any equipment has been added to the vehicle or if any modifications have been made to the vehicle that increase its speed or power We also advise you to strictly follow the recommended maintenance program outlined in this manual This preventive maintenance program is designed to ensure that all critical components on the vehicle are thoroughly inspected by your dealer at various mileage in...

Page 10: ...8 NOTES ...

Page 11: ...9 TABLE OF CONTENTS Vehicle Identification Numbers 11 Safety 12 Features and Controls 36 Operation 47 Noise Emission 55 Maintenance and Lubrication 56 Specifications 96 Troubleshooting 98 Warranty 100 ...

Page 12: ...10 NOTES ...

Page 13: ... spare key and store in a safe place The vehicle frame vehicle identifaction number VIN and engine serial number are important for model identification when registering your vehicle when obtaining insurance and when ordering replacement parts In the event your vehicle is stolen these numbers are essential to the recovery and identification of your vehicle Vehicle Model Number Dealer Imprint VIN ...

Page 14: ... on your 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 machine CAUTION NOTE A note will alert you to important information or instructions A caution indicates a situat...

Page 15: ...safety components before each ride Polaris UTVs are designed to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The UTV may become aerodynamically unstable at speeds higher than those for which it is designed Loss of control may occur at high...

Page 16: ...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 machine for possible damage including but not limited to brakes throttle and steering WARNING ...

Page 17: ...rating 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...

Page 18: ...rt or gravel In many states it s illegal to operate vehicles of this type on public streets roads and highways 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 Never consume alcohol or ...

Page 19: ...OTENTIAL 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 Safe operation of this vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturns and los...

Page 20: ...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 21: ...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 22: ... control accident HOW TO AVOID THE HAZARD Improper installation of accessories or modification of this vehicle may cause changes in handling that in some situations could lead to an accident Never modify this vehicle through improper installation or use of accessories All parts and accessories should be genuine Polaris Sales Inc or equivalent components designed for use on the vehicle and they sho...

Page 23: ...g Under these conditions follow these precautions 1 Slow down when entering slippery areas 2 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 3 Correct a skid by turning the steering wheel in the direction of the skid 4 Drive with AWD engaged to assist in controlling the vehicle CAUTION Engaging AWD while the wheels are spinning can cause se...

Page 24: ... 1 Drive straight uphill 2 Avoid steep hills 3 Keep both feet on the floor 4 Proceed at a steady rate of speed and throttle opening 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 Avoid...

Page 25: ... the vehicle could occur Avoid climbing steep hills 15_ maximum Use extreme care when operating your vehicle in hilly terrain WARNING 15_ Maximum Improperly crossing hills or turning on hills could cause loss of control or vehicle overturn If at all possible avoid crossing the side of a steep hill Avoid hills with excessively slippery or loose surfaces WARNING ...

Page 26: ...lways dry the brakes by applying light pressure to the lever until braking action is normal NOTE After running the vehicle in water it is critical that your machine is serviced as outlined in the Periodic Maintenance Schedule beginning on page 56 Give special attention to engine oil transmission oil front and rear gearcases and all grease fittings CAUTION Should your vehicle become immersed take i...

Page 27: ... on the righthand side of the trail and be constantly alert for hazards such as logs rocks and low hanging branches Hidden or unseen hazards on the trail can be dangerous Personal injury or the vehicle overturning can occur from unseen obstacles Stay alert and constantly look for obstacles on the trail WARNING ...

Page 28: ...d turning at sharp angles in reverse 5 Never open the throttle suddenly while backing 6 Always inspect left and right fields of vision before backing Backing your UTV can be dangerous You could collide with an obstacle or person behind you or the vehicle could overturn on a steep incline Always back slowly avoiding excessive speed Avoid backing on steep inclines WARNING ...

Page 29: ...incline always block the rear wheels on the downhill side Always check to be sure that the parking brake has been disengaged before operating the vehicle An accident could result if the parking brake is left on while the vehicle is operated Always block the downhill side of the wheels if leaving the vehicle on a hill or park the vehicle in a sidehill position WARNING ...

Page 30: ...0 lbs 681 kg 1000 lbs 454 kg Load Distribution 1 Always load the cargo box with the load as far forward as possible 2 Always operate the vehicle with extreme care when hauling or towing loads 3 Slow down and drive in low gear Never operate this vehicle with the cargo box in the raised position The cargo box could close unexpectedly while driving severely injuring the driver The rear tires will cat...

Page 31: ...arked on an incline 2 Set the parking brake 3 Press and hold the cargo box dump 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 Never carry passengers in the cargo box Passengers should always ride in the cab with seat belts fastened securely WARNING ...

Page 32: ...in high gear Drive belt life will be affected Maximum grade while trailer towing is 15 Do not tow any trailer on a grade steeper than 15 Never carry a passenger in a trailer 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 the recommended weight...

Page 33: ...vehicle If the vehicle should roll it may cause damage or injury WARNING 3 Remove the ignition switch key to prevent unauthorized use NOTE 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 lights Gasoline is extremely flammable and can be explosive under...

Page 34: ...king when carrying cargo Overloading or carrying tall off center or unsecured loads will 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 7079425 Location 1 S Moving pa...

Page 35: ...uent cleaning required in dusty conditions D Operation of this vehicle without engine breather filter s can cause engine damage Consult owner s manual for details D Specific carburetor jetting and adjustments are required depending on temperature and altitude See your Owner s Manual Factory setting 40_ to 80_ F at 0 3000 feet 5_ to 27_ C at 0 900 meters 7079902 4 Location 4 ...

Page 36: ... POUR SERVICE HORS ROUTE QUI NEST PAS DES TINE A ETRE UTILISE SUR LES CHEMINS PUBLICS Remove flammable containers from box before refueling Location 5 under hood Location 6 inside front of box 5 6 Fuel Passenger Warning Decal Text Remove flammable containers from box before refueling S Passengers can be thrown off This can cause serious injury or death S Never carry passengers in cargo box Maximum...

Page 37: ...and brakes gradually ALWAYS S Avoid paved surfaces which may adversely affect handling and con trol 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 ...

Page 38: ...36 FEATURES AND CONTROLS Features 1 Cab Frame 2 Cab Frame Hand Hold 3 Dashboard 4 Steering Wheel 5 Seat 6 Cargo Box 7 Seat Belts 8 Fuel Tank Cap Fuel Gauge 9 Battery under seat 1 4 7 5 6 2 3 8 9 ...

Page 39: ...37 FEATURES AND CONTROLS Features 12 11 10 10 13 13 10 Headlights 11 Radiator 12 Front Bumper Brush Guard 13 Hood Hold Down Strap ...

Page 40: ...16 16 22 20 18 15 23 14 21 21 19 17 14 Oil Tank 15 Battery Under Seat 16 Tail Lights 17 Tail Gate 18 Tailgate Latch Release 19 Airbox under cargo box 20 Muffler Spark Arrester 21 Rear Caliper 22 Trailer Hitch Receiver 23 Engine Oil Plug ...

Page 41: ...on page 30 Seat Belts The vehicle is equipped with lap style seat belts for the operator and passenger Seat belts reduce injury Always wear your seat belt Minimum age recommendation for passengers is five years old Passengers under five years of age require special restraints which are not available with this vehicle WARNING To wear the seat belt properly follow this procedure 1 Place the belt acr...

Page 42: ...e pins are fully seated into the grommets Fuel Cap Fuel Gauge The fuel tank filler cap 1 is located on the righthand 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 indicator needle nears the E empty mark refuel at the earliest opportunity When refueling always use either leaded or unleaded gasoline with a mi...

Page 43: ...2 1 3 4 5 9 8 6 10 1 Choke Knob 2 Ignition Switch 3 Hour Meter 4 Indicator Lights 5 12V Accessory Plug 6 Fog High Beam Light Switch 7 AWD All Wheel Drive Switch if equipped 8 Shift Lever 9 Differential Lock Lever 10 Cargo Box Dump Switch ...

Page 44: ...ed above idle or while 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 shi...

Page 45: ...crease engine speed Spring pressure returns the pedal to the rest position when released Always check that the throttle pedal returns normally before starting the engine In addition there must be adequate throttle pedal play Refer to page 79 for throttle pedal adjustment procedure Indicator Lights There are indicator lights on the dash panel for the following 1 High 2 Low 3 Neutral 4 Reverse 5 Hig...

Page 46: ...r manual disengagement instructions Cargo Box Dump Switch 4 The cargo box can be dumped or lowered by holding the dump switch down to dump or up to lower 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 engaged by holding ignition switch key in this position Upon release the key will return to the...

Page 47: ...en the rear wheels regain traction the front wheels will automatically disengage The AWD switch position indicates when the vehicle is in AWD There is no limit to the length of time the vehicle may remain in AWD The AWD switch may be turned on or off while the vehicle is moving If the switch is turned off when the front hubs are driving they will not release until the rear wheels regain traction C...

Page 48: ...o the released position Make sure the parking brake lever is functioning properly before each operation Differential Lock The rear axle is equipped with a lockable differential that allows the operator to choose between an open differential or a closed differential It s beneficial to lock the differential in low traction situations The differential lever is located on the console 3 Pull the lever ...

Page 49: ...des emergency parking brake 4 Throttle check for free operation and closing 5 Headlight Taillight Brakelight check operation of all 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 op...

Page 50: ...ation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and other important areas on the vehicle as outlined on the daily pre operation inspection checklist found on page 47 6 Pull only light loads 7 Break in oil and filter Change both at 25 hours CAUTION Mixing oil brands or using non recommended oil may cause engine dama...

Page 51: ...ing operation WARNING Procedure for Starting a Cold Engine 1 Place the transmission in neutral 2 Lock the parking brake 3 Sit in the driver s seat and fasten your seat belt 4 Pull the choke knob all the way out 5 Turn the ignition key to START 6 If the engine does not start within five seconds release the ignition switch and wait five seconds Turn the ignition switch to START for another five seco...

Page 52: ...low recommended engine starting procedures Carbon monoxide exhaust gas is poisonous Always start the vehicle outdoors Never run the engine in an enclosed area WARNING The engine exhaust from this product contains chemicals known to cause cancer birth de fects or other reproductive harm WARNING ...

Page 53: ...king brake 3 Sit in the driver s seat with the seat belt fastened 4 Turn the ignition key to START 5 If the engine has cooled and does not readily start 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 NO...

Page 54: ...throttle and brakes on level surfaces Braking 1 Release the throttle pedal completely 2 Press on the brake pedal evenly and firmly NOTE Practice starting and stopping using the brakes until you are 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 CAUTION Low is the primary gear for operating thi...

Page 55: ... completely and brake to a complete stop 2 Put the gear shift lever into neutral 3 Apply the parking brake to help prevent the vehicle from rolling Always apply the parking brake before leaving the vehicle Movement may result in damage or personal injury WARNING ...

Page 56: ...d alcohol Gasoline containing methanol must also be blended with cosolvents and corrosion inhibitors n Never use gasohol for extended periods and never store this vehicle with gasohol in the fuel system n Gasoline containing alcohol can cause paint damage Do not spill gasohol during refueling Gasoline is highly flammable and is explosive under certain conditions Always exercise extreme caution whe...

Page 57: ...NSTITUTE 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 Do not touch hot exh...

Page 58: ...s the need for replacement parts use genuine Polaris parts available from your Polaris dealer Item Frequency Remarks Brake System Pre operation Inspect Tires Pre operation Inspect Wheels Pre operation Inspect Frame nuts bolts fasteners Pre operation Inspect Parking Brake Pre operation Check lever adjustment daily ad just Throttle Cable Pre operation Inspect Steering Pre operation Inspect Coolant L...

Page 59: ...d Cylinder Base Fasteners 25 hrs Re torque required at first service only Engine Oil Level 25 hrs Check level daily break in service at 25 hours L Engine Oil Change 4 Cycle 100 hrs Change oil at 100 hours more often in cold weather use L Oil Filter 100 hrs Replace with oil change L Engine breather hose 100 hrs Inspect J Carburetor Float Bowl 50 hrs Drain bowl periodically and prior to storage J Th...

Page 60: ...ired J L Fuel System 100 hrs Check for leaks at fuel cap lines fuel valve filter pump and carbure tor Replace lines every two years J 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...

Page 61: ...itting and grease with grease gun 50 hours Ball Joint Grease Locate fitting on back side of struts and grease with grease gun 50 hours 3 Swing Arm Bushings Grease Locate fittings on swing arm and grease with grease gun 25 hours Rear angle drives GL5 80 90 weight gear lube Fill to bottom thread of filler hole Make certain machine is on a level surface 50 hours 4 Front A Arm Pivot Shaft Grease Locat...

Page 62: ...60 MAINTENANCE AND LUBRICATION Lubrication Recommendations 1 2 3 4 ...

Page 63: ...ent 6 Remove the dipstick and check to see that the oil level is between the full and add marks 2 Add oil if necessary Do not overfill ADD 8 OZ NORMAL FULL 1 2 CAUTION Mixing oil brands or using non recommended oil may cause engine damage If using non recommended engine oil is determined to have caused engine damage repair and or replacement will not be covered under Polaris warranty We recommend ...

Page 64: ...OTE Severe use cold weather operation is when all operating is at below 10 F and or when operating between 10 F and 30 F if most trips are slow speed and less than five miles Always change the oil filter when changing oil PROCEDURE 1 Position the vehicle on a level surface 2 Clean the area around the drain plug at the bottom of the oil tank 3 Run the engine for two to three minutes until warm Turn...

Page 65: ... 10 Using a clean dry cloth clean the filter sealing surface on the crankcase 11 Lubricate the o ring on the new filter with a film of new engine oil Check to make sure the o ring is in good condition Also make sure the o ring from the old filter is not still on the engine 12 Install the new filter 3 and tighten by hand 1 2 to 3 4 turn after gasket contact 13 Approximately one cup of engine oil wi...

Page 66: ...cle engines It is a fully synthetic high performance multi viscosity oil designed to provide the ultimate in lubrication performance and protection Premium 4 possesses unsurpassed film strength over the widest possible temperature range It resists viscosity and frictional breakdown in ambient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation m...

Page 67: ...y 1 Position the vehicle on a level surface 2 Remove the fill plug 1 which is located on the righthand side of the machine 3 Check the lubricant level Lubricant should be kept at the bottom of the fill plug threads NOTE We recommend the use of Polaris Premium Synthetic Gearcase Lubricant for optimum performance CAUTION Do not allow dirt or foreign materials to enter the transmission case ...

Page 68: ...r possible failure of the front grease components NOTE We recommend the use of Polaris Premium Hub Oil for optimum performance The front gearcase fill plug 1 is located on the right side of the front gearcase 1 With the UTV on a level surface remove fill plug and check the lubricant level Lubricant should be kept at the bottom thread of the fill plug hole 2 Support vehicle securely with a jack sta...

Page 69: ...e radiator filler neck radiator pressure cap and connecting hose As coolant operating temperature increases the expanding heated excess coolant is forced out of the radiator past the pressure cap and into the overflow bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the tank past the pressure cap and into the radiator NOTE Some coolant level drop ...

Page 70: ...vel has reached the maximum mark Reinstall the cap NOTE Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolant and distilled water NOTE Polaris Premium 60 40 is already premixed and ready to use Do not dilute with water NOTE Always follow the manufacturer s mixing recommendations for the freeze protection r...

Page 71: ...ment contact your dealer for the correct replacement part Changing Coolant To ensure that the coolant maintains its ability to protect the engine the system be completely drained every two years and a fresh mixture of antifreeze and water should be added Polaris recommends the use of Polaris Premium 60 40 anti freeze coolant or a 50 50 mixture of high quality aluminum compatible anti freeze coolan...

Page 72: ...rference with the radiator 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 Pe...

Page 73: ...esponsibility of the owner Always follow recommended maintenance procedures See your dealer This PVT system is intended for use on Polaris products only The PVT housing must be securely in place during operation Failure to comply with this warning can result in severe injury or death WARNING PVT Drying There may be some instances when water is accidently ingested into the PVT system Use the follow...

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 machine 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: ...here tightly to the cover and seal all the way around 3 Remove the air filter Do not attempt to clean the main element 4 Install a new air filter NOTE Apply a small amount of general purpose grease to the sealing edges of the filter before installing 5 Check the air box If oil or water deposits are found drain them into a suitable container NOTE Service more frequently if vehicle is operated in we...

Page 76: ...ilter in the direction of the arrow to check for clogging Replace as needed 4 Check hoses for cracks deterioration abrasion or leaks Replace as needed 5 Reinstall the filter and clamps with the arrow pointing toward the engine Do not perform this operation immediately after the engine has been run The exhaust system becomes very hot and can cause severe burns WARNING 1 2 CAUTION Operation of your ...

Page 77: ...ray tan or light brown There will be few combustion deposits and the electrodes will not be 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 an improper spark plug or incorrect carburetion adjustments Wet Fouled Plug On a wet fouled plug the insulator tip is black A d...

Page 78: ...dure for spark plug installation Torque to 17 ft lbs 2 3 kg m Cylinder Head Cylinder Base Fastener Torque Have your dealer check the UTV cylinder head and cylinder base fasteners for proper torque at the first service or after 25 hours The exhaust system or engine can cause serious burns Always wait for the engine to cool before removing spark plugs WARNING CAUTION Always use the spark plugs recom...

Page 79: ...noxide gas Do not go under the machine while it is inclined Failure to heed these warnings could result in serious personal injury or death WARNING 1 Remove the arrestor clean out plugs 1 located on the bottom of the muffler 2 Place the transmission in neutral and start the engine Purge accumulated carbon from the system by momentarily revving the engine several times 3 If some carbon is expelled ...

Page 80: ...front of the machine is one foot higher than the rear Set the parking brake and block the wheels Make sure the machine is in neutral and repeat steps 2 and 3 NOTE See WARNING above 6 Repeat steps 2 through 5 until no more particles are expelled when the engine is revved 7 Stop the engine and allow the arrestor to cool 8 Reinstall the arrestor plugs ...

Page 81: ...the play if necessary Throttle Freeplay 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 Adjustment 1 Slide the boots 1 off the inline cable adjuster sleeve 2 Loosen the adjuster locknut...

Page 82: ... are favorable the carburetor can be adjusted with the following procedure 1 Apply the 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 desire...

Page 83: ...r 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 around the fittings 1 CAUTION Change the fluid in the brake system completely if the fluid level is below the minimum or if the type and brand o...

Page 84: ...he ignition switch to the ON position 2 Depress the brake pedal The brake light should come on after about 10mm 0 4 in of pedal travel If the light doesn t come on check the bulb 3 64 1 cm If the brake pedal has a spongy feeling when applied there may be air in the brake lines or the brake may be defective Do not operate the vehicle under these conditions Have the brake system serviced by an autho...

Page 85: ...nt 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 the adjustment bolt until the rear tire will not rotate 5 Back the adjustment bolt out 1 4 turn 6 Tighten the jam nut while holding the adjustment nut i...

Page 86: ...tly turn 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 in the direction required to increase or decrease...

Page 87: ...ris dealer The UTV seat 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 N...

Page 88: ... 35 ft lbs Center and Rear Hub Retaining Nut s 120 ft lbs Rear Wheel Nuts 35 ft lbs Operating your vehicle with worn tires will increase the possibility of skidding loss of control and an accident Always replace tires when the tread depth measures 1 8 3 cm or less WARNING CAUTION Always maintain proper tire pressure Improper tire inflation may affect vehicle maneuverability When replacing tires al...

Page 89: ...n 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 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 86 CAUTION If wheels are improperly i...

Page 90: ...and switch on the headlight 4 Observe the headlight aim The most intense part of the headlight beam should be aimed 8 20 3 cm below the mark placed on the wall in step 2 NOTE Include the weight of a rider on the seat while performing 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...

Page 91: ...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 dash 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 scre...

Page 92: ...r parts last Rinse with water frequently and dry with a chamois to prevent water spots NOTE If warning labels are damaged contact your Polaris dealer for free replacement If a high pressure type car wash system is used extreme care must be taken to avoid water damage to the wheel bearings transmission seals body panels brakes headlights and warning labels Many expensive repair bills can result fro...

Page 93: ...battery Store it in a cool dry place out of the sun 4 Lubricate suspension pivot points lower steering post and rear axle fittings 5 Drain the engine side cover 6 Block the vehicle so all tires are suspended off the ground 7 Spray oil on all unpainted metal surfaces to prevent rusting Avoid getting oil on rubber parts or in the brakes 8 Lubricate all cables 9 Tie a plastic bag over the exhaust pip...

Page 94: ...3 Fill the fuel tank with fuel 4 Check all the points listed in the Daily Pre Operation Inspection section beginning on page 47 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 Do not run the engine in a closed area Exhaust gases contain carbon monoxide a colorless odorless poisonous ...

Page 95: ...cup water Rinse well with tap water and dry off with clean shop towels Coat the terminals with dielectric grease or petroleum jelly CAUTION Whenever removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negative black cable last 1 CAUTION Use only distilled water when refilling a battery Tap water contains minerals that are harmful t...

Page 96: ...rolyte 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 Batteries produce explosive gases Keep sparks flame...

Page 97: ...ive cable 4 Second connect and tighten the black negative cable 5 Verify that cables are properly routed NOTE When your UTV is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool dry place Before reusing take the battery to your dealer for testing and recharging CAUTION If electrolyte spills immediately wash it off with a solution o...

Page 98: ...10 in Minimum Turning Radius 132 in 132 in Engine Oil Capacity 2 qts 2 qts Coolant Capacity 2 25 qts 2 25 qts Engine 4 valve 4 stroke single cylinder with counter balance 4 valve 4 stroke single cylinder with counter balance Displacement 425 cc 499 cc Bore x Stroke 87 9 x 70 92 x 75 Pilot Jet 42 5 42 5 Main Jet 135 142 5 Needle Jet P 6 829 P 6 829 Jet Needle 4LC38 3 4MB32 3 Air Screw 2 1 4 2 1 2 A...

Page 99: ...re Pressure Rear 10 psi 10 psi Brake Foot Activated 4 Foot Activated 4 Brake Foot Activated 4 wheel hydraulic disc Foot Activated 4 wheel hydraulic disc Front Hydraulic disk float ing caliper Hydraulic disk float ing caliper Rear Hydraulic disk float ing caliper with me chanical parking brake Hydraulic disk float ing caliper with me chanical parking brake Parking Brake Foot activated mechanical Fo...

Page 100: ...tact Your Dealer ENGINE STOPS OR LOSES POWER No Fuel Contact Your Dealer Contact Your Dealer Overuse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Water in Fuel Air Filter Clogged Fuel Vent Line Kinked or Plugged Clean Radiator screen Fuel Pump Faulty Contact Your Dealer Plugged fuel line or fuel filter ...

Page 101: ...em Under certain conditions it may be possible for the AWD system to remain engaged 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 into reverse and back up a minimum of 10 feet 3 Come to a complete stop 4 Shift into forward and drive If the hubs remain engaged after following these i...

Page 102: ... please contact your dealer immediately 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 REMEDIE...

Page 103: ...IOD POLARIS FURTHER DISCLAIMS 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...

Page 104: ...ment 89 Indicator Lights 41 43 Lights 88 89 Light Switch 44 Load Distribution 28 Lubrication Recommendations 59 60 MAINTENANCE LUBRICATION 56 95 Maintenance Schedule 56 58 Muffler 38 NOISE EMISSION 55 Oil and Filter Change 62 64 Oil System 61 64 Oil Tank 38 OPERATION 47 54 Operator Safety 12 31 Operating in Reverse 26 Operating on Hills 22 23 Parking Brake Adjustment 83 Parking Brake Inspection 83...

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