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118

MAINTENANCE AND LUBRICATION

Lubrication

Transmission Oil Changing Procedure

1. Remove the four screws on the footwell and gently pull outward

for access. Remove propshaft shield from the right side of the

vehicle (Scrambler 500 4x4, Xplorer 4x4).

2. Remove fill plug.

3. Remove transmission drain plug located on the bottom left hand

side and drain the oil (refer to page 117 for the location of the

Magnum drain plug). Catch and discard used oil properly.

4. Clean and reinstall the drain plug torque to 14 ft. lbs. (1.93 kg-m).
5. Add the correct amount of Polaris Premium Synthetic Gearcase

Lubricant until oil reaches the bottom of the filler hole.

6. Check for leaks.

7. Reinstall propshaft shield or footwell and screws removed in step

Содержание ATV 2002

Страница 1: ......

Страница 2: ...own to cause cancer birth de fects or other reproductive harm A card containing important safey information should be attached to the owner s manual on the next page If you cannot locate this card or...

Страница 3: ...Indicates a potential hazard that could result in serious injury or death WARNING...

Страница 4: ...ted a web site just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it out www polarisindustrie...

Страница 5: ...for safe and enjoyable operation of your vehicle Your Owner s Manual contains instructions for minor maintenance Major repairs are covered in the Polaris Service Manual and should be performed by a Fa...

Страница 6: ...FETY TRAINING When you purchased this vehicle your dealer offered a hands on safety training course covering all aspects of ATV safety In addition you were provided with certain printed material which...

Страница 7: ...Issues 8 Decals and Locations 12 Operator Safety 22 Features and Controls 43 65 Controls 43 Features 58 Operation 66 70 Pre Ride Inspection 66 Vehicle Break In Period 67 Starting the Engine 70 Carryi...

Страница 8: ...commendations 94 Maintenance Record 100 Cooling System 101 Lubrication 104 Filter Systems 127 Adjustments 130 Lights 146 Spark Plugs 153 Water Service 154 Spark Arrestor 155 Recoil Housing 157 PVT 158...

Страница 9: ...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 important f...

Страница 10: ...manual The safety alert symbol on your vehicle or in this manual alerts you to the potential for personal injury Indicates a potential hazard that could result in serious injury or death Indicates a p...

Страница 11: ...available at the time of printing Polaris Industries Inc reserves the right to make product changes and improvements which may affect illustrations or explanations No part of this manual shall be rep...

Страница 12: ...lso wear eye protection goggles or face shield gloves boots long sleeved shirt or jacket and long pants S Never consume alcohol or drugs before or while operating this ATV S Never operate at excessive...

Страница 13: ...this manual on level ground Avoid crossing the side of a steep hill if possible S Always use proper procedures if you stall or roll backwards when climbing a hill To avoid stalling maintain a steady s...

Страница 14: ...c Polaris hereby strongly recommends and requests that consumers not have installed on a Polaris ATV any equipment which is intended to increase the speed or power of the vehicle or make any other mod...

Страница 15: ...your protection Read and follow the instructions on each decal carefully In the event any decal becomes illegible or comes off contact your Polaris dealer for a replacement Any safety decal needing r...

Страница 16: ...13 SAFETY Safety Decals and Locations 1 7079083 E1997 2000 IF OWNER S MANUAL IS MISSING CONTACT YOUR POLARIS DEALER FOR A REPLACEMENT WARNING...

Страница 17: ...14 SAFETY Safety Decals and Locations 2 3...

Страница 18: ...prevent flipover avoid sudden braking or sharp turns F Use OVERRIDE for reverse speed limiter with caution To prevent loss of control never activate override button with open throttle F PARKING BRAKE...

Страница 19: ...16 SAFETY Safety Decals and Locations 4 5 6...

Страница 20: ...S Reduce speed and allow greater distance for braking when carrying cargo Overloading or carrying tall off center or unsecured loads will increase your risk of losing control Loads should be centered...

Страница 21: ...lt 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 which can...

Страница 22: ...ecals and Locations 9 9 DO NOT TOW FROM RACK OR BUMPER Vehicle damage or tipover may result causing severe injury or death Tow only from tow hooks or hitch Maximum Rack Loads Front 90 lbs Rear 180 Lbs...

Страница 23: ...verse override is controlled by the override switch See your Owner s Manual OVERRIDE SWITCH 7079906 AWD Models 2WD Models 7077542 TRAILER MAX WEIGHT 1225 LBS 556 KG ON LEVEL GROUND 850 LBS 368 KG UP T...

Страница 24: ...tional 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 helmet face shield offer...

Страница 25: ...rse and the operating techniques described in the Owner s Manual For more information about the training course contact an authorized ATV dealer or call Polaris at 1 800 342 3764 POTENTIAL HAZARD Fail...

Страница 26: ...rol this ATV Could cause an accident resulting in harm to you and or your passenger HOW TO AVOID THE HAZARD Never carry a passenger The long seat is to allow the operator to shift position as needed d...

Страница 27: ...AN 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 Avoid o...

Страница 28: ...eets 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 states...

Страница 29: ...r chances of a severe head injury or death in the event of an accident Operating without eye protection can result in an accident and increases your chances of a severe injury in the event of an accid...

Страница 30: ...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 HAPPEN Increases y...

Страница 31: ...NTIAL 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 jumps...

Страница 32: ...ures and schedules described in the Owner s Manual POTENTIAL HAZARD Removing hands from handlebars or feet from footrests during operation WHAT CAN HAPPEN Removing even one hand or foot can reduce you...

Страница 33: ...T 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 caref...

Страница 34: ...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 until you...

Страница 35: ...t 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 easily on ext...

Страница 36: ...ribed in the Owner s Manual See pages 80 through 83 Always check the terrain carefully before you start up any hill Never climb hills with excessively slippery or loose surfaces Shift your weight forw...

Страница 37: ...oing down hills as described in the Owner s Manual See page 82 NOTE A special technique is required when braking as you go downhill Always check the terrain carefully before you start down any hill Sh...

Страница 38: ...any hill until you have mastered the turning technique as described in the Owner s Manual on level ground See page 83 Be very careful when turning on any hill Avoid crossing the side of a steep hill i...

Страница 39: ...hill 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 the s...

Страница 40: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Страница 41: ...voiding sudden movements maintain a slow and steady forward motion do not make sudden turns or stops and do not make sudden throttle changes Remember that wet brakes may have reduced stopping ability...

Страница 42: ...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 vehicle may...

Страница 43: ...ling a trailer Allow greater distance for braking Always follow the instructions in the Owner s Manual for carrying cargo or pulling a trailer See pages 72 through 74 POTENTIAL HAZARD Riding on frozen...

Страница 44: ...arge obstacles such as large rocks or fallen trees If you cannot avoid obstacles always follow proper procedures as described in the Owner s Manual POTENTIAL HAZARD Skidding or sliding WHAT CAN HAPPEN...

Страница 45: ...r physical disabilities who operate this vehicle have an increased risk of overturns and loss of control which could result in severe injury or death WARNING WARNING Leaving the keys in the ignition c...

Страница 46: ...ine Stop Switch The engine will not start or run when the switch is in its off position Its purpose is to provide the operator with a quick means of engine shutdown in case of stuck throttle or other...

Страница 47: ...s will cease when the operator releases the throttle lever Choke Refer to the engine starting procedure on page 70 for correct choke and throttle settings during starting Do not start or operate an AT...

Страница 48: ...t brake lever travel and reservoir fluid level before riding When squeezed the lever should feel firm Any sponginess would indicate a possible fluid leak or low master cylinder fluid level which must...

Страница 49: ...straight If the fluid level is low add DOT 3 PN 2870990 only The Electronic Throttle Control ETC stops the engine in the event of a throttle system malfunction and is provided for your safety Do not...

Страница 50: ...Important Safeguards S The parking brake may relax when left on for a long period of time This could cause an accident S Do not leave the vehicle on a hill depending on the parking brake for more tha...

Страница 51: ...ressure to brake the rear wheels without skidding Aggressively applying the rear brake when backing down a hill may cause rear tip over Brake Fluid Level It will be necessary to check the brake fluid...

Страница 52: ...F For vehicle storage and whenever transporting ON For normal operation RES For reserve supply in the event of main supply exhaustion NOTE There is about a 7 to 10 mile 11 2 to 16 km range on reserve...

Страница 53: ...ed or where gasoline is stored S Do not over fill the tank Do not fill the tank neck S If you get gasoline on your skin or clothing immediately wash it off with soap and water and change clothing S Ne...

Страница 54: ...hine Refer to your Owner s Manual Supplement to determine the type of engine your vehicle has The tank capacity is 2 quarts 1 9 l On models with a two cycle engine use only Polaris injection oil Never...

Страница 55: ...nual Supplement for specification NOTE To extend belt life use low forward gear in heavy pulling situations and in situations where you are operating below 7 miles per hour for extended periods of tim...

Страница 56: ...f in Reverse to find neutral Refer to the gear shift pedal illustrated on this page Once the vehicle is in neutral start the engine by engaging the starter Brake Start This model also has a brake star...

Страница 57: ...up follow this procedure 1 With the transmission in neutral hold the brake lever 2 With the throttle closed raise the gear shift pedal one full stroke to shift into first gear 3 Release the brake leve...

Страница 58: ...required for vehicle movement S Avoid turning at sharp angles in reverse S Avoid backing on steep inclines Light Switches and Indicator Lights Be careful when operating in reverse Make certain your pa...

Страница 59: ...brakes smoothly and evenly As you slow down shift to a lower gear Be certain the engine has sufficiently slowed before engaging a lower gear Improper use of the brakes or shifting can cause the tires...

Страница 60: ...inning fast enough to start and restores compression for starting 1 Be certain your vehicle is on a level surface and the parking brake is set See page 74 2 Take the machine out of gear 3 Grasp the re...

Страница 61: ...wheels regain traction the front wheels will automatically disengage NOTE The override switch also allows activation of Demand 4 Drive AWD in reverse if Demand 4 Drive switch is on There is no limit t...

Страница 62: ...wheel hubs are engaged steering effort increases but remains balanced from left to right and vehicle speed is somewhat restricted NOTE If the hubs remain engaged after following these instructions ret...

Страница 63: ...ion 1 Transmission Neutral Green 2 Transmission Reverse Yellow 3 Oil Warning Red On 2 cycle models this light indicates a low oil level 4 High Temp Red Will light only if engine overheats 5 All Wheel...

Страница 64: ...rip Miles 000 0 M Hours 00000 0 H To reset Trip Miles 1 Toggle to Trip Miles 2 Hold down button approximately 4 seconds The speedometer also has additional features accessed through a sub menu These f...

Страница 65: ...once to scroll through the four available functions Each function will be displayed as follows Service Hours SET hr Service Distance SETdIS Miles to Kilometers COnvrT No Menu Changes DOnE Changing Di...

Страница 66: ...the 50 hour service setting example from above the speedometer will take the 50 hour setting and add it to the value of the hour meter This will be the value displayed when the operator checks when se...

Страница 67: ...y The reminder will remain in the LCD window until the button is pushed or it is reprogrammed for the next service interval When this is done the display will return to the normal menu showing odomete...

Страница 68: ...ccessories such as hand held spot lights On select models an outlet is located on the front headlight pod To determine if your vehicle is equipped with auxiliary power outlet please check your Owner s...

Страница 69: ...unction 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element...

Страница 70: ...lined on page 49 2 Fill the oil tank with Polaris injection oil 3 Drive slowly at first Select an area which is open and will give you room to familiarize yourself with vehicle operation and handling...

Страница 71: ...r the first tank of pre mixed fuel has been used please verify that the oil level in the oil tank has dropped indicating that the oil pump is functioning properly If the level has not dropped see your...

Страница 72: ...t an area which is open and will give you room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fl...

Страница 73: ...and can be adjusted gradually depending on how much choke is needed for starting 7 Do not press the throttle while starting the engine 8 Activate the starter for a maximum of five seconds releasing th...

Страница 74: ...reduce moisture accumulation in the oil tank when the ATV is operated in freezing temperatures If you use your ATV all year round it is important to check your oil level frequently A rising oil level...

Страница 75: ...weight 30 lbs 14 kg Select models may tow up to 1225 556 kg on level ground only with a maximum vertical hitch weight of 35 lbs 16 kg Refer to your Owner s Manual Supplement to determine your machine...

Страница 76: ...ack only increases the possibility of vehicle tip over S HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations w...

Страница 77: ...rely fasten load and operate with ex tra caution Always attach the tow load to the hitch point designated for your ATV S EXTREME CAUTION MUST BE USED when operating with loads extending over the rack...

Страница 78: ...val 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 induct...

Страница 79: ...nction 7 Wheels check for tightness of wheel nuts and axle nuts check that axle nuts are secured by cotter pins 8 Drive chain condition and slack refer to drive chain adjustment 9 Air cleaner element...

Страница 80: ...r 3 Check your surroundings and determine your path of travel 4 Release the parking brake 5 Slowly depress the throttle with your right thumb and begin driving Vehicle speed is controlled by the amoun...

Страница 81: ...e wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the ou...

Страница 82: ...e skid and shifting your body weight forward 4 Driving with Demand 4 Drive All Wheel Drive engagedcan assistin controlling the vehicle in slippery areas 5 Never apply brakes during a skid Complete los...

Страница 83: ...steady rate of speed and throttle opening 5 Remain alert and be prepared to take emergency action This may include quick dismounting of the ATV Indicates a potential hazard that could result in serio...

Страница 84: ...he hill transferring your upper body weight toward the hill while keeping your feet on the footrests 3 Steer slightly into the hill to maintain vehicle directions If vehicle begins to tip quickly turn...

Страница 85: ...ar 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 Do no...

Страница 86: ...turn handlebars full 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...

Страница 87: ...d water which exceeds the recommended maxi mum depth go slowly balance your weight carefully avoid sud den movements maintain a slow and steady forward motion Do not make sudden turns or stops and do...

Страница 88: ...you ride Stay on the right side of the trail if possible and be constantly alert for hazards such as logs rocks and low hanging branches Not all obstacles are visible Travel with caution on trails se...

Страница 89: ...of control may result NOTE Most Polaris ATVs are equipped with a reverse speed limiter The override button should be used with caution as rearward vehicle speed is greatly increased Do not operate at...

Страница 90: ...ace the transmission in gear or in park 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...

Страница 91: ...an lubricate adjust or replace parts as necessary NOTE Inspection may reveal the need for replacement parts Always use genuine Polaris parts available from your Polaris dealer Service and adjustments...

Страница 92: ...on Pre ride Pre ride Replace engine coolant every two years Fuel and oil tanks Pre ride Pre ride Fill to proper levels Throttle Pre ride Pre ride Check operation Lights Pre ride Pre ride Check operati...

Страница 93: ...Counterbal ance 400 Engines 20 hrs Monthly Check oil level change annually L Engine breather filter 4 cycle 20 hrs Monthly Inspect replace annually and as needed J Brake pad wear 10 hrs Monthly Inspe...

Страница 94: ...Enricher Cable 50 hrs 6 months Inspect adjust lubricate replace if necessary Coolant strength pressure test system 100 hrs 6 months Inspect strength seasonal ly pressure test system annually Front hu...

Страница 95: ...J L Ignition Timing 100 hrs 12 months Inspect and adjust as needed J L Fuel System 100 hours 12 months Check for leaks at tank cap lines fuel valve filter pump and carburetor Re place lines every two...

Страница 96: ...x H L R 200 hrs 24 months Change lubricant every two years J Brake fluid 200 hrs 24 months Change every two years J Front wheel bearings 2wd 300 hrs 36 months Inspect replace if neces sary L Idle Spee...

Страница 97: ...t 100 hours 5 Front Gearcase Oil GL5 80 90 Weight Gear Lube See Page 122 Models with Visco drive require special lubricant See your owner s manual sup plement for requirement Change annually or at 100...

Страница 98: ...MAINTENANCE AND LUBRICATION Lubrication Recommendations Operating Range Full 4 Transmission dipstick 6 Front Prop Shaft U Joint Fill plug 5 Front Gear Case 4 Transmission plug 7 Propshaft Yoke Fill pl...

Страница 99: ...ith grease gun Every 3 months or 50 hours 12 Front A Arm Pivot Shaft L Grease Locate fitting on pivot shaft and grease with grease gun Every 3 months or 50 hours 13 Counter Balance Housing 400 SAE 10...

Страница 100: ...BRICATION Lubrication Recommendations 10 Axle Cardan Front Drive AWD Models 13 Counterbalance Dipstick 14 Steering Post Bushing 11 Ball Joint 12 Front A Arm Pivot Shaft Upper 9 4 O clock position 9 De...

Страница 101: ...r L Grease Locate fitting and grease Semi annually 20 Rear Anti Roll Bar L Grease Locate fitting and grease Semi annually L More often under severe use such as wet or dusty conditions Polaris Premium...

Страница 102: ...CATION Lubrication Recommendations 16 Swing Arm Bushings 15 Rear Axle Bearing 17 Upper Control Arm 19 Rear Wheel Hub Bearing Carrier 20 Rear Anti Roll Bar 18 Lower Control Arm INDEPENDENT REAR SUSPENS...

Страница 103: ...UBRICATION 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 5...

Страница 104: ...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 on new machines is normal as the system is purging itse...

Страница 105: ...I A To access the pressure cap clean the area around the oil cap and remove the oil cap 2 cycle models Remove front cover by placing your fingers under the front of the cover and pulling upward Reinst...

Страница 106: ...and a fresh mixture of antifreeze and water 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 coolant...

Страница 107: ...ubrication demands of today s high performance 2 cycle engines These are optimum oils recommended for liquid cooled and air cooled 2 cycle engines We believe these oils are the best available in the m...

Страница 108: ...ient temperatures from 40 F to 120 F Its exceptional frictional properties result in more efficient operation more power output lower fuel consumption and easier starting in cold temperatures Although...

Страница 109: ...upplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise 4 Lift boot 1 up off adjuster...

Страница 110: ...s to open See Owner s Manual Supplement 3 Place very slight pressure on the throttle lever until all freeplay is removed from throttle cable to the point where the carb slide is just starting to rise...

Страница 111: ...e jam nut You will need to bottom the cable to the carburetor slidevalve cap Adjust at throttle cable adjuster near the throttle block See page 137 for adjustment procedure Oil and Filter Change The r...

Страница 112: ...lug NOTE The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 17 ft lbs 1 93 2 35 kg m 8 Disconnect the...

Страница 113: ...plug found on lower right side of crankcase NOTE The sealing surfaces on the drain plug and crankcase should be clean and free of burrs nicks or scratches 14 Reinstall drain plug 15 Remove dipstick an...

Страница 114: ...drain completely 6 Replace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to...

Страница 115: ...and set parking brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the l...

Страница 116: ...aling surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Place shop towels beneath oil filter Using an o...

Страница 117: ...or one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick 16 Dispose of used f...

Страница 118: ...lace sealing washer on drain plug NOTE The sealing surfaces on drain plug and crankcase should be clean and free of burrs nicks or scratches 7 Reinstall drain plug and torque to 14 ft lbs 1 9 kgm 8 Pl...

Страница 119: ...g brake 14 Start the engine and let it idle for one to two minutes Stop the engine and inspect for leaks 15 Re check the oil level on the dipstick and add oil as necessary to bring the level to the up...

Страница 120: ...miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a level surface remove fill plug 1 and check the lubricant level Use the illustration and the chart belo...

Страница 121: ...g 3 Remove transmission drain plug located on the bottom left hand side and drain the oil refer to page 117 for the location of the Magnum drain plug Catch and discard used oil properly 4 Clean and re...

Страница 122: ...is located near the rear brake disc The transmission lubricant level should be checked monthly or 1000 miles 1600 km whichever comes first Transmission oil should be changed annually With the ATV on a...

Страница 123: ...lt B in to allow the removal of drain plug C 5 Remove the drain plug and wipe the magnetic end clean to remove accumulated metallic filings 6 After the oil has drained completely install a new sealing...

Страница 124: ...ug dipstick 2 Remove transmission drain plug side and drain the oil Catch and discard used oil properly 3 Clean and reinstall the drain plug 4 Add 32 oz 948 ml Polaris Premium Synthetic Gearcase Lubri...

Страница 125: ...ant to use is GL5 80 90 Weight Gear Lube Type B The lubricant level in this type of gearcase cannot be checked You must periodically drain it and refill it according to the following procedure Gearcas...

Страница 126: ...eads The correct gearcase lubricant to use is GL5 80 90 Weight Gear Lube Oil Changing Procedure 1 Remove drain plug 3 Catch and discard used oil properly 2 Clean and reinstall the drain plug with a ne...

Страница 127: ...uld be added or changed as necessary The oil should be changed annually especially before off season storage If the machine is used in wet conditions the oil should be checked more frequently If the o...

Страница 128: ...the dipstick If overfilled excess oil will be expelled through the vent hose 4 Reinstall dipstick NOTE Recommended Oil Level 2 Counter Balance Oil Changing Procedure 1 Remove skid plate 2 Remove count...

Страница 129: ...0 30 seconds 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 angl...

Страница 130: ...r 5 Wash pre filter in soapy water rinse and let dry 6 Re install pre filter over main filter Replace main filter if required Filter Installation Procedure 1 Check condition of airbox and replace if n...

Страница 131: ...ure of 40 PSI Always use a dispersion type nozzle to prevent filter damage and clean from the inside to the outside NOTE Replace the air filter every 50 hours and possibly more often in very dirty con...

Страница 132: ...ine 2 Inspect filter for debris Blow through gently in direction of arrow on filter to check for clogging Replace as needed 3 Check hoses for cracks deterioration abrasion or leaks Replace as needed 4...

Страница 133: ...e Alignment You can check the toe alignment of the vehicle using the following method The recommended toe alignment is 1 8 to 1 4 3 to 6 cm toe out If you discover improper adjustment have your dealer...

Страница 134: ...s side surface of the rear tires on each side of machine and goes around the stands in front of the machine 4 Measure from string to rim at front and rear of front rim Rear rim measurement should be 1...

Страница 135: ...djustment The rear shock absorber spring is adjusted by rotating the adjuster in the direction required to increase or decrease spring tension NOTE Accessory springs are available through your Polaris...

Страница 136: ...t Be sure 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 eq...

Страница 137: ...ated and the diaphragm should be replaced Always fill the reservoir as indicated whenev er the cover is loosened or removed to insure proper diaphragm operation Use Polaris DOT 3 brake fluid S Check b...

Страница 138: ...orn to 3 64 1 cm which is about the thickness of a dime S Inspect the brake disc spline and pad wear surface for excessive wear Auxiliary Brake Systems Your ATV s auxiliary brake system is intended to...

Страница 139: ...carburetor idle screw in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM The following variations to ai...

Страница 140: ...w A in or out until the desired idle RPM is reached Turning the screw in clockwise will raise RPM Turning the screw out counterclockwise will lower RPM Throttle Cable Free Play Adjustment Throttle cab...

Страница 141: ...AND LUBRICATION Adjustments Cylinder Head Cylinder Base Fastener Torque 2 Cycle Models Have your dealer check the ATV cylinder head and cylinder base fasteners for proper torque at the first service o...

Страница 142: ...e handling and tire wear Wheel Removal Procedure 1 Stop the engine place the transmission in gear and lock the parking brake 2 Loosen the wheel nuts slightly 3 Elevate the side of the vehicle by placi...

Страница 143: ...2 Attach the wheel nuts and finger tighten them 3 Lower the vehicle to the ground 4 Securely tighten the wheel nuts according to the chart found on page 140 The following items should be checked occa...

Страница 144: ...itical component operations Service work must be performed by your authorized Polaris dealer Tire Inspection When replacing a tire always use original equipment size and type Tire Tread Depth Always r...

Страница 145: ...r Always inspect the drive chain prior to operating the vehicle checking for damaged or missing O rings rollers and correct slack adjustment Maintain the stone guard to rear sprocket clearance at 1 8...

Страница 146: ...rd to gain slack at the top side of the rear chain At this point the chain should have 3 16 3 8 48 cm 95 cm deflection 1 If the chain needs adjustment use the following procedure Never adjust or opera...

Страница 147: ...hout the hitch and 45 ft lbs 13 7 kg m for machines with a hitch 7 Tighten caliper mount bolts 10 12 ft lbs 1 4 1 7 kg m 8 Remove pin punch 9 Roll ATV foward checking chain tension in several places a...

Страница 148: ...etting to compensate for altitude and or temperature changes 2 Transmission convertor modification to adjust for engine horsepower loss during high altitude operation Contact your dealer 3 On 2 cycle...

Страница 149: ...g and rotate clockwise firmly NOTE Bulb is to be positioned so the harness installs into the lamp at the bottom 4 Reinstall connector Keep your headlights and taillights clean Poor lighting while ridi...

Страница 150: ...the headlight and make a mark on the wall at the same height 3 Start the engine and turn the headlight switch to high beam 4 Observe headlight aim The most intense part of the headlight beam should be...

Страница 151: ...l surface with the headlight approximately 25 7 6 m from a wall 2 Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height 3 Start the engine a...

Страница 152: ...pod 4 Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 5 Unplug headlamp from wiring harness 6 Remove boot and locking collar fr...

Страница 153: ...with the headlight approximately 25 7 6 m from a wall 2 Measure the distance 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 t...

Страница 154: ...pod 5 Lift pod cover up Disconnect speedometer harnesses from speedometer Unplug indicator light harness and remove pod cover 6 Unplug headlamp from wiring harness 7 Remove O Ring from headlight pivo...

Страница 155: ...moved in step 1 Indicator Lamp Replacement Style I 1 Remove the upper headlight pod Gen 4 or the front cover Gen 2 to access the back of the indicator panel 2 Using a small straight blade screwdriver...

Страница 156: ...used by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fouled The insulator tip is black A damp oil film covers the firing end There may be a carbon layer over the entire nos...

Страница 157: ...electric start S Dry the spark plug and reinstall or re place with a new plug S Tighten the carburetor drain screw 1 or reinstall carburetor drain 2 S Reinstall crankcase drain S Turn the fuel valve t...

Страница 158: ...hen cleaning the spark arrestor you must follow the safeguards listed below to avoid serious injury or death S Do not perform this operation immediately after the engine has been run because the exhau...

Страница 159: ...in neutral and repeat steps 2 and 3 5 If particles are still suspected to be in the muffler drive the machine onto the incline so the front of the machine is one foot higher than the rear Set the park...

Страница 160: ...ravelling in wet areas the recoil housing and starter should always be drained completely by removing the recoil Do not open the crankcase drain unless the engine has ingested water On 4 cycle engines...

Страница 161: ...Extensive engineering and testing has been conducted to insure the safety of this product However as the owner you have the following responsibilities to make sure this system remains safe S Do not m...

Страница 162: ...clutch covers to fail By switching to low range while operating at low ground speeds the air temperature in the clutch cover is reduced by almost 160 degrees Reducing the temperature inside the clutch...

Страница 163: ...lists provide a guideline for when to use low range rather than high Low Range S Basic operation at speeds less than 7 MPH S Heavy pulling S Riding through rough terrain swamps mountains etc at low g...

Страница 164: ...situation could result causing serious injury or death WARNING Battery electrolyte is poisonous It contains sulfuric acid Serious burns can result from contact with skin eyes or clothing Antidote Exte...

Страница 165: ...e of corrosion If cleaning is necessary remove the corrosion with a stiff wire brush Wash with a solution of one tablespoon baking soda and one cup water Rinse well with tap water and dry off with cle...

Страница 166: ...hold down strap 6 Verify that cables are properly routed NOTE S When your ATV is placed in storage for three months or more the battery should be removed charged to proper level and stored in a cool d...

Страница 167: ...pull the panel forward and outward to disengage the two rear tabs 2 Place hand on top of side panel behind the fuel tank With a quick and firm motion push down on the side panel to disengage the top r...

Страница 168: ...ngs immediately after washing Also run the vehicle to evaporate any water that might have entered the engine or exhaust system The best and safest way to clean your ATV is with a garden hose and a pai...

Страница 169: ...for the stabilizer to disperse through the fuel in the tank and carburetor Turn the fuel valve to OFF and drain the carburetor bowl completely Oil And Filter Change 4 Strokes Warm the engine and chang...

Страница 170: ...Chain Lube to the drive chain s Battery Maintenance Remove the battery and add distilled water as required to the proper level Do not use tap water which may contain minerals that reduce battery life...

Страница 171: ...the fuel system with Polaris Carbon Clean 5 If Polaris fuel system additive is not used fuel tank fuel lines and carburetor should be completely drained of gasoline to eliminate any fuel remaining in...

Страница 172: ...of Low Range is high ly recommended for cooler PVT oper ating temperatures and longer compo nent life Insufficient warm up of ATVs exposed to low ambi ent temperatures Warm engine at least 5 min then...

Страница 173: ...e peat several times as required During this procedure the throttle should not be held at the full posi tion for more than 10 seconds Clutch seals should be inspected for damage if repeated leaking oc...

Страница 174: ...uses for questions you may have about the operation of your ATV See your Polaris dealer with any additional questions you may have ENGINE TURNS OVER BUT FAILS TO START No Fuel Water in Fuel Spark Plug...

Страница 175: ...veruse of Choke Spark Plug Fouled Engine Overheated Clean Engine Exterior Turn Fuel Valve to Res Water in Fuel Air Filter Clogged Reverse Speed Limiter Malfunction Electronic Throttle Control Malfunct...

Страница 176: ...the time of sale the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days Upon receipt of this registration Polaris will record the registration for wa...

Страница 177: ...rosion or defects in parts components or the ATV due to fire explosions or any other cause beyond Polaris control This warranty does not cover the use of unauthorized lubricants chemicals or fuels tha...

Страница 178: ...ce you must present your copy of the Warranty Registration form to the dealer THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY Polaris suggests that you use your original selli...

Страница 179: ...Fuel Stabilizer 166 Fuel System 49 51 Fuel Valve 49 Gearcase Oil Changing Procedure 122 Handlebar Adjustment 133 Headlight Adjustment 147 150 Headlight Lamp Replacement 146 149 Indicator Lamp Replace...

Страница 180: ...tion 117 119 Transmission Oil Changing Procedure 118 121 Transporting 168 Traveling Downhill 82 Traveling Uphill 80 Troubleshooting 169 172 Turning Around On a Hill 83 Understanding Warnings 7 Vehicle...

Страница 181: ......

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