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

Transcription

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

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4 2 -NOTES-

5 WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Polaris proudly produces an exciting line of recreational products, including snowmobiles, all-terrain vehicles, personal watercraft, utility vehicles, and Victory motorcycles. We believe Polaris sets the standard of excellence for all vehicles manufactured in the world today. Many years of experience in engineering, design, and development have gone into making your UTV the finest machine we ve ever produced. Follow the instructions and recommendations in this Owner s Manual for safe and 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 during, and after, the warranty period. Polaris also takes great pride in our PAA (Parts Apparel and Accessories) which are available in our online store at Have your accessories and clothing delivered right to your door! Polaris and Polaris The Way Out are registered trademarks of Polaris Industries Inc. Copyright 2002 Polaris Industries Inc. All Rights Reserved Printed in the U.S.A. 3

6 THIS VEHICLE IS NOT A TOY AND CAN BE HAZARDOUS TO OPERATE. This vehicle handles differently from other vehicles, including motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers such as turning and driving on hills or over obstacles if you fail to take proper precautions. SEVERE INJURY OR DEATH can result if you do not follow these instructions: n Read this manual and all labels carefully. Follow the operating procedures described. n Never allow anyone without a valid driver s license to operate this vehicle. n 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. Driver and passenger should wear their seat belts at all times. n Never permit a guest to operate this vehicle 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 an aggressive manner. Eye protection is recommended at all times. n Never consume alcohol or drugs before or while operating this vehicle. n Never operate at excessive speeds. Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. n Never attempt wheelies, jumps or other stunts. n Always inspect your vehicle each time you use it to make sure it s in safe operating condition. Always follow the inspection and maintenance procedures and schedules described in this manual. n Always keep both hands on the steering wheel and both feet on the floorboards of the vehicle during operation. 4

7 n Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain. n Never operate on excessively rough, slippery or loose terrain. n Always follow proper procedures for turning as described in this manual. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds. n Always have this vehicle checked by an authorized Polaris dealer if it has been involved in an accident. n Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. n Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly or make sudden gear changes. Never go over the top of 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 crossing the side of a hill as described in this manual. Avoid hills with excessively slippery or loose surfaces. Never attempt to turn the vehicle around on any hill until you have mastered (on level ground) the turning technique described in this manual. Avoid crossing the side of a steep hill if possible. n 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. n Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control. 5

8 n Never operate your vehicle in fast-flowing water or in water deeper than that specified in this manual. Wet brakes may have reduced stopping ability. Test your brakes after leaving water. If necessary, apply them lightly several times to let friction dry out the pads. n Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it s safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse. n Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on page 97. n Never modify this vehicle through improper installation or use of accessories. n Never 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 legs inside the cab frame while the vehicle is in motion. n Always apply the parking brake before getting out of the vehicle. Seepage46. n Always activate the foot pedal brake before releasing the park brake. n Always turn off the engine before refueling. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Gasoline is extremely flammable. See page 54 for refueling instructions. FOR MORE INFORMATION ABOUT SAFETY, call Polaris at

9 Additional Important Information We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris UTV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the UTV substantially increase the risk of bodily injury. Modifications may create a substantial safety hazard. The warranty on your Polaris UTV is terminated 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 intervals. NOTE: The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Be sure any accessories added to this vehicle have been approved by Polaris, and familiarize yourself with their function and effect on the vehicle. 7

10 8 -NOTES-

11 TABLE OF CONTENTS Vehicle Identification Numbers Safety Features and Controls Operation Noise Emission Maintenance and Lubrication Specifications Troubleshooting Warranty

12 10 -NOTES-

13 VEHICLE IDENTIFICATION NUMBERS 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. VIN NOTE: Remove the spare key and store in a safe place. Important: Record your vehicle s identification numbers in the spaces provided. Frame VIN: Vehicle Model Number: Engine Serial Number (right front side of engine crankcase) Dealer Imprint 11

14 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your UTV. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, 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. CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the machine. CAUTION A caution indicates a situation that may result in damage to the machine. NOTE A note will alert you to important information or instructions. 12

15 SAFETY Operator Safety Driving a UTV requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving. They will reduce your alertness and slow your reaction time. In most states and provinces, it s prohibited by law to drive while intoxicated or under the influence of drugs. Make sure your UTV is in excellent operating condition at all times. We strongly recommend that the operator check all 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 higher speeds. Modifications may also create a safety hazard and lead to bodily injury. The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the UTV. 13

16 SAFETY Operator Safety POTENTIAL HAZARD Stalling, rolling backwards while climbing a hill WHAT CAN HAPPEN Vehicle overturn HOW TO AVOID THE HAZARD Maintain a steady speed when climbing a hill. Ifyouloseallforwardspeed: 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. 14

17 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle on paved surfaces WHAT CAN HAPPEN Loss of control HOW TO AVOID THE HAZARD This vehicle s tires are designed for off-road use only, not for use on pavement. Paved surfaces may seriously affect handling and control of the vehicle, and may cause the vehicle to go out of control. Avoid operating the vehicle on pavement. If you must operate on a paved surface, travel slowly and do not make sudden turns or stops. 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 different types of terrain. All operators must read and understand the Owner s Manual and all warning and instruction labels on the vehicle. 15

18 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle on public streets, roads or highways WHAT CAN HAPPEN Collision with another vehicle HOW TO AVOID THE HAZARD Never operate this vehicle on any public street, road or highway, including dirt or gravel. In many states it s illegal to operate vehicles of this type on public streets, roads and highways. 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 drugs before or while driving this vehicle. 16

19 SAFETY Operator Safety 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 loss of control, which could result in serious injury or death. POTENTIAL HAZARD Operating this vehicle at excessive speeds WHAT CAN HAPPEN Loss of control, accident HOW TO AVOID THE HAZARD Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience. 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. 17

20 SAFETY Operator Safety POTENTIAL HAZARD Failure to inspect the vehicle before operating Failure to properly maintain the vehicle WHAT CAN HAPPEN Accident, equipment damage HOW TO AVOID THE HAZARD Always inspect your UTV before each use to make sure it s in safe operating condition. Always follow the 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 vehicle. You may come upon hidden rocks, bumps, or holes suddenly, without enough time to react. 18

21 SAFETY Operator Safety 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 recommended, he or she may not have the skills, abilities, or judgment needed to operate the vehicle safely and may be involved in a serious accident. POTENTIAL HAZARD Operating this vehicle with improper tires or with improper or uneven tire pressure WHAT CAN HAPPEN Loss of control, accident and/or overturn HOW TO AVOID THE HAZARD Always use the size and type of tires specified in the Owner s Manual for this vehicle. See page 97. Always maintain proper tire pressure as described on the decal and in the Owner s Manual. See page

22 SAFETY Operator Safety POTENTIAL HAZARD Operating this vehicle with improper modifications WHAT CAN HAPPEN Loss of 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 should be installed and used according to instructions. See your authorized Polaris dealer. In the event of an accident, have a qualified service dealer inspect the complete machine for possible damage, including (but not limited to) brakes, throttle, and steering. 20

23 SAFETY Operator Safety Driving On Slippery Surfaces Extra caution is required when operating on slippery surfaces. Loss of tire traction and vehicle control can result in an accident, including an overturn. Never apply brakes during a skid. Complete loss of control can result. Avoid operating on excessively slippery surfaces. Always reduce speed and use additional caution. When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. 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 severe damage to the drive train. Before operating your vehicle on a frozen body of water, be sure the ice is thick enough to support the machine and its operator, as well as the force created by a moving vehicle. Severe injury or death can result if the vehicle and/or its operator break through the ice. 21

24 SAFETY Operator Safety Operating on Hills Climbing hills improperly can cause loss of control or vehicle overturn. Always check the terrain carefully before climbing a hill. Never climb hills with excessively slippery or loose surfaces. Never open the throttle suddenly. Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill. When traveling uphill: 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 descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible. When descending a hill: 1. Drive directly downhill. 2. Slow down. 3. Apply the brakes lightly to aid in slowing. 22

25 SAFETY Operator Safety Operating on Hills 15_ Maximum Braking and handling are greatly affected when operating in hilly terrain. Loss of vehicle control or overturning of the vehicle could occur. Avoid climbing steep hills (15_ maximum). Use extreme care when operating your vehicle in hilly terrain. 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. 23

26 SAFETY Operator Safety Crossing Streams Never try to cross a deep or fast-flowing stream. The large tires can cause the vehicle to float, resulting in loss of control. Your Polaris UTV can operate through water up to depths reaching the floorboards. Before fording streams: 1. Always determine water depths and current. 2. Always choose a crossing where both banks have gradual inclines. 3. Always proceed slowly, avoiding rocks and obstacles. 4. After crossing, always 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 it to your dealer as soon as possible for service. Do not start the engine! Immersion can result in major damage if not correctly serviced. If this is impossible, service your machine as outlined on page 72, and take the machine to your dealer at your first opportunity. 24

27 Operator Safety SAFETY Trail Obstacles Stay alert! Look ahead and learn to read the trail as you drive. Stay 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. 25

28 SAFETY Operator Safety Operating in Reverse 1. When backing up, always avoid backing downhill. 2. Back slowly. 3. When in reverse, apply the brakes lightly for stopping. 4. Avoid 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. 26

29 SAFETY Operator Safety ParkingOnAnIncline 1. Place the transmission in gear. 2. Set the parking brake. 3. Avoid parking on an incline. If it is necessary to park on an 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. 27

30 SAFETY Operator Safety Carrying Loads The UTV has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. Never exceed the following capacities. Maximum Capacities (Level Ground) Cargo Box UTV 2X lbs. (614 kg) 850 lbs. (386 kg) UTV 4X 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 catch the rear of the box, damaging the vehicle and creating hazardous driving conditions. Do not overload the vehicle. 28

31 Operator Safety SAFETY Dumping the Cargo Box 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked 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. 29

32 SAFETY Operator Safety Towing Loads Maximum Towing Capacities (Level Ground) Total Towed Load Weight (level ground) Total Towed Load Weight (15 grade) Total Hitch Vertical Weight Towing Speed UTV 2X lbs. (636 kg) 800 lbs. (364 kg) 150 lbs (68.1 kg) 10 mph (16 kph) or less UTV 4X lbs. (681 kg) 850 lbs. (386 kg) 150 lbs (68.1 kg) 10 mph (16 kph) or less Do not tow 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. See page 96. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location or you may lose control of the vehicle. 30

33 SAFETY Operator Safety Parking the UTV 1. Stop the vehicle on a level surface. 2. When the engine has stopped, apply the parking brake to help prevent the vehicle from rolling. Always apply the parking brake before leaving the vehicle. If the vehicle should roll, it may cause damage or injury. 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 certain conditions. 31

34 SAFETY Safety Decals and Locations S VEHICLE ROLLOVER could cause severe injury or death This cab frame is not designed or intended to provide rollover protection. S ALWAYS WEAR YOUR SEAT BELT for maximum protection Location 1 S Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. S Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM which can result in serious injury or death Location 2 NO STEP 32 IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. TIRE PRESSURE (PSI): FRONT 10 REAR 10 MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, DRIVER AND CARGO IS 2750 LBS. 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 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. Location 3 Read Owner s Manual for more detailed loading information

35 Safety Decals and Locations SAFETY D D D Operation of this vehicle without the filter element will severely damage the engine. Clean air filter often, more frequent cleaning required in dusty conditions Operation of this vehicle without engine breather filter(s) can cause engine damage. Consult owner s manual for details. Location 4 ATTENTION 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 feet (5_ to 27_ C. at meters)

36 SAFETY Safety Decals and Locations MANUFACTURED BY: POLARIS IND INC. DATE: VIN: 5 THIS VEHICLE IS A GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE AND IS NOT INTENDED FOR USE ON PUBLIC ROADS. CE VÉHICULE USAGE GENERAL VEHICULE UTILIT- AIRE POUR SERVICE HORS ROUTE QUI NEST PAS DES- TINE A ETRE UTILISE SUR LES CHEMINS PUBLICS. PRINTED IN U.S.A Location 5 (under hood) 6 Remove flammable containers from box before refueling. Location 6 (inside, front of box) 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. Maximum2x4BoxLoad850lbs. Maximum4x4BoxLoad1000 lbs. 34

37 Safety Decals and Locations SAFETY Location 7 Warning Decal Text Improper vehicle use can result in SEVERE INJURY or DEATH. NEVER: S Operate on public roads. A collision can occur with another vehicle. S Carry more than two passengers, or passengers under age five. S Use ALCOHOL or DRUGS before or while operating this vehicle. S Operate at speeds too fast for your skills or the conditions. S Operate this vehicle on HILLS steeper than 15 degrees. To prevent flipover on hilly terrain, use throttle and brakes gradually. 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 an emergency or parking brake only. READ OWNER S MANUAL. FOLLOW ALL INSTRUCTIONS AND S. IF OWNER S MANUAL IS MISSING, CONTACT A POLARIS DEALER FOR A REPLACEMENT. THIS GENERAL PURPOSE OFF-ROAD UTILITY VEHICLE DOES NOT MEET FEDERAL MOTOR VEHICLE SAFETY STANDARDS FOR ON ROAD VEHICLES. 7 35

38 FEATURES AND CONTROLS Features 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) 36

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

40 FEATURES AND CONTROLS Features 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 38

41 Features FEATURES AND CONTROLS Auxiliary Lighting/Electrical Accessory Terminals The 12-volt receptacle (1) has spade connections on the back that may be used to power an auxiliary light or other optional lights or accessories. To locate these connections, lift the hood and look behind the dash board. Trailer Hitch Bracket This vehicle is equipped with a 1 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 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. To wear the seat belt properly, follow this procedure: 1. Place the belt across 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. 39

42 FEATURES AND CONTROLS Features Seat Removal Pull up on the front of the seat and slide it toward the front of the vehicle. Install the seat by sliding the tabs into the rear of the seat base. Push down firmly on the front of the seat until the 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 minimum pump octane number of 87 R+ M/2 octane. 1 40

43 Controls FEATURES AND CONTROLS 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 41

44 FEATURES AND CONTROLS Controls Transmission Gear Selector Operation The transmission gear selector (1) is located on the console to the right of the steering wheel. It has four positions (2): high, low, neutral and reverse. NOTE: Low is the primary driving range for this vehicle. High is intended for use on hard packed surfaces with light loads. To change gears, stop the vehicle and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle 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 shifted to reverse. Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always place the transmission in gear with the parking brake applied and turn the vehicle off whenever the vehicle is left unattended. 1 CAUTION 2 H L N R 42

45 Controls FEATURES AND CONTROLS Brake Pedal The brake pedal (1) is the left pedal on the foot board. Depress the brake pedal to slow or stop the vehicle. Throttle Pedal The throttle pedal (2) is the right pedal on the floor board. 2 Push the pedal down to 1 increase 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. High Temperature 6. Brakes H L N R BRAKE

46 FEATURES AND CONTROLS Controls Ignition Switch (1) The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. 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 ON position. CAUTION Do not operate the starter continuously for more than five seconds or the starter will overheat and the battery power will drop temporarily. Wait at least five seconds between each operation of the starter to allow it to cool and to allow battery power recovery. Do not turn the ignition switch key to the START position while the engine is running. Damage to the starter can result. Light Switch (2) Turn the headlights and taillights on by flipping the light switch up (the ignition switch key must be in the ON position). Flip the switch down to turn the lights off. AWD Switch (3) Vehicles equipped with AWD can be operated in either 2WD or AWD. Flip the AWD switch up to engage the AWD. Flip the switch down to return to 2WD. Under some conditions, it s possible for the AWD to remain engaged. See page 99 for 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). 44

47 Controls FEATURES AND CONTROLS All Wheel Drive (AWD) Your Polaris UTV 4X4 is equipped with an exclusive Polaris All Wheel Drive (AWD) system that can be activated by a switch on the dash. When the switch is off, the UTV is in two-wheel drive at all times. When the switch is on, the UTV is in AWD, and the front wheels will automatically engage any time the rear wheels lose traction. When 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. CAUTION If the rear wheels are spinning, release the throttle before turning the AWD switch on. If AWD is engaged while the wheels are spinning, severe drive shaft and clutch damage could result. 45

48 FEATURES AND CONTROLS Controls Parking Brake Lever The parking brake (1) is located below the dash in the center of the vehicle. It will help prevent the vehicle from rolling while parked. To apply the parking brake, push down on the pedal with your foot. To release, pull the release handle (2), which is located below the dash. 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 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 down to lock CAUTION Damage to the differential can occur if it is engaged when the vehicle is traveling at high speeds or while the rear wheels are spinning. 46

49 OPERATION Before You Ride Daily Pre-operation Inspection If a proper inspection is not performed, serious injury or death can result. Always inspect your UTV before operating. Inspect your vehicle before each operation to ensure it s in proper working order. Before operating your vehicle, inspect all operating controls and parts. Item/Inspection Procedure 1. Tires - check condition and pressures 2. Fuel and oil tanks - fill both tanks to their proper levels 3. All brakes - check operation, adjustment and fluid level (includes 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 operation noting any unusual looseness in any area 10. Loose parts - visually inspect vehicle for any damaged or loose nuts/bolts or fasteners 11. Operator and passenger should be properly dressed. 12. Engine coolant - check for proper level in the overflow bottle. 13. Check condition and operation of the dump box/bed latch mechanism. 47

50 OPERATION Vehicle Break-In Period The break-in period for your new Polaris UTV is the first twenty hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine will result in more efficient performance and longer life for the engine. Perform the following procedures carefully. 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 the use of Polaris Premium 4 All Season Synthetic Oil or API certified SH oil. Never mix oil brands. 1. Fill the fuel tank with either unleaded or leaded fuel that has a minimum pump octane number of 87= (R+ M)/2. ADD 8 OZ. NORMAL FULL 2. Check oil reservoir level indicated on dipstick. Add oil if necessary. Maintain Oil Level In Normal Range 3. Drive slowly at first. Select an open area that will give you room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. CAUTION Operating at full throttle or high speeds for extended periods during the first three hours of use may cause excessive heat, resulting in damage to close-fitted engine parts. 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 Pull only light loads. 7. Break in oil and filter. Change both at 25 hours. 48

51 OPERATION Starting the Engine Do not start or operate this vehicle with sticking or improperly operating throttle pedal. Doing so could cause an accident leading to severe injury or death. Always contact your dealer for service repairs if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle pedal sticks during operation. Always check the pedal for free movement and return before starting the engine and occasionally during operation. 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 seconds. Repeat this procedure until engine starts. NOTE: Do not press the throttle pedal while starting the engine. 7. If the engine slows or stops, push the choke knob in half way. 8. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly. Then push the choke all the way in. 49

52 OPERATION Starting the Engine CAUTION Improper engine warm-up may cause engine damage. Follow recommended engine starting procedures. Carbon monoxide exhaust gas is poisonous! Always start the vehicle outdoors. Never run the engine in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. 50

53 Starting the Engine OPERATION Procedure for Starting a Warm Engine Warm engines do not normally require the use of the choke. Overuse of the choke can cause the spark plug to become wet fouled. 1. Place the transmission in neutral and move the vehicle to a level surface. 2. Lock the parking 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. NOTE: If the engine does not start and all conditions are favorable, change the spark plug. 51

54 OPERATION Driving the UTV 1. Sit in the driver s seat with the seat belt fastened. 2. After starting the engine and allowing it to warm up, shift the transmission into gear. CAUTION Low is the primary gear for operating this vehicle. High gear is intended for use on hard-packed surfaces with light loads. Premature belt wear may result from operating in a gear that s unsuitable for the terrain. 3. Check your surroundings and determine your path of travel. 4. Release the 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. When carrying cargo or towing a trailer, load weight will increase braking distances. Failure to allow for increased braking distance may result in accident and injury. 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. 52

55 Stopping the Engine OPERATION 1. Release the throttle pedal 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. 53

56 OPERATION Refueling Gasoline is highly flammable and is explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always stop the engine when refueling. Always refuel outdoors or in a well ventilated area. 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 consciousness and death in a short time. Gasoline and Alcohol Blends Blends of gasoline and alcohol called gasohol may be used on an occasional basis, but continued use is not recommended. Immediately switch back to gasoline, which does not contain alcohol, if you experience any operating irregularities. Any deterioration of fuel system components or degradation of performance resulting from the use of gasohol is not covered by Polaris Warranty. n Never use gasohol with an octane rating lower than the minimum octane rating specified for this product. Always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+ M/2 octane. n Never use gasohol containing more than 10% ethanol (grain alcohol). n Never use gasohol containing more than 5% methanol (wood 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. 54

57 NOISE EMISSION CONTROL SYSTEM REGULATION TAMPERING WITH NOISE CONTROL SYSTEM PROHIBITED! U.S. Federal law prohibits the following acts or the causing thereof: 1. The removal or rendering inoperative by any person other than for purposes of maintenance, repair, or replacement of any device or element of design incorporated into any new vehicle for the purpose of noise control prior to its sale or delivery to the ultimate purchaser or while it is in use or 2. The use of the vehicle after such device or element of design has been removed or rendered inoperative by any person. AMONG THOSE ACTS PRESUMED 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. CAUTION Exhaust system components are very hot during and after use of the vehicle and will cause burns if they come in contact with skin. Do not touch hot exhaust system components. Serious burns can result. Use extra caution when traveling through tall grass. The potential for fire exists. USFS Approved Spark Arrestor The muffler on this vehicle was tested and approved in accordance with the USFS Forest Service Standard A. 55

58 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 are not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: When inspection reveals the need for replacement parts, use genuine Polaris parts available from your Polaris dealer. CAUTION Due to the nature of adjustments indicated by a J, itis recommended that service be performed by an authorized Polaris dealer. Do not attempt to perform this work unless you are familiar with mechanical repair. Item Frequency Remarks Brake System Pre-operation Inspect Tires Pre-operation Inspect Wheels Pre-operation Inspect Frame nuts, bolts, Pre-operation Inspect fasteners Parking Brake Pre-operation Check lever adjustment daily; adjust Throttle Cable Pre-operation Inspect Steering Pre-operation Inspect Coolant/Level Daily Replace coolant every two years Headlamp Daily Inspect operation daily; apply Polaris dielectric grease to connector when replaced " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) 56

59 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule " L Item Frequency Remarks Tail lamp Daily Check daily; apply Polaris dielectric grease to socket when replaced AirFilter-MainElement Weekly Inspect; replace if necessary " Transmission Oil 25 hrs Check level; change oil annually Battery 25 hrs Check terminals; clean; check fluid level J Brake pad wear 25 hrs Inspect periodically " L Engine breather filter 25 hrs Inspect, replace annually and as needed " General Lubrication 25 hrs Lubricate all fittings, pivots, cables, etc. Engine Cylinder Head/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 " L L Engine Oil - Change (4-Cycle) 100 hrs Change oil at 100 hours, more often in cold weather use. Oil Filter 100 hrs Replace with oil change Engine breather hose 100 hrs Inspect J 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 " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California - 4-Cycle) 57

60 MAINTENANCE AND LUBRICATION Periodic Maintenance Schedule Item Frequency Remarks J Steering 50 hrs Inspect; lubricate " Front Suspension 50 hrs Inspect; lubricate, tighten fasteners " Rear Suspension 50 hrs Inspect, tighten fasteners Coolant strength/ pressure test system Engine Mounts 100 hrs Inspect 100 hrs Inspect strength seasonally; pressure test system annually J Valve Clearance 100 hrs Inspect; adjust L L Spark Plug 100 hrs Inspect; replace if necessary J L Ignition Timing 100 hrs Inspect and adjust as needed J Front Hub Bearings 100 hrs Check at 100 hours and replace as required J L Fuel System 100 hrs Check for leaks at fuel cap, lines, fuel valve, filter, pump and carburetor. Replace lines every two years. J Fuel Filter 100 hrs Replace annually Cooling System 100 hrs Inspect hoses Spark arrestor 100 hrs Clean out " Front Gearcase Oil 100 hrs Check monthly; change annually J Clutches (drive and 100 hrs Inspect, clean driven) 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 Engine side cover As required Drain moisture after driving in water J Toe adjustment As required Periodic inspection, adjust when parts are replaced Headlight Aim As required Adjust if necessary " More often under severe use, such as dirty or wet conditions L Emission Control System Service (California) 58