Position the vehicle on a level surface. Do not attempt to dump or unload the vehicle while parked on an incline. Dismount the vehicle. Lower the tailgate. If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. Page Emission Control Systems Spark Arrestor Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.
Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. Record maintenance and service in the Maintenance Log beginning on page Page Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission-related service Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
Have an authorized Polaris dealer perform these services. Page 72 36 M Clean out Toe adjustment Inspect periodically; adjust when parts are replaced Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use. Page Oil Recommendations See page for the part numbers of Polaris products. Oil may need to be changed more frequently if Polaris Premium 4 oil is not used.
Follow the manufacturer's recommendations for ambient tem- perature operation. Allow it to idle for 30 seconds.
Remove the dipstick. Wipe it dry with a clean cloth. Do not allow hot oil to contact skin. Disconnect the lower oil deliv- ery hose and remove the screen fitting from the oil tank. Clean the fitting. Add 1. NOTE: If the sump is not drained, add about 1. Reinstall the dipstick. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the Clamp Use the recommended oil. See page for the part numbers of Polaris products.
Remove the fill plug. Remove the drain plug. Drain the oil into a drain pan. Clean the drain plug. Page Fluid Level Use the recommended fluid.
Fill Plug Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole Fill Level threads. Drain Plug Fluid Level 1. Drain the fluid into a drain pan. Do not dilute with water. See page for the part num- bers of Polaris products. Never remove the pressure cap while the engine is warm or hot.
Open the front box cover. Open the access door. Remove the radiator pressure cap. Page Brake Fluid Never operate the Quadricycle with spongy- feeling brakes. If the fluid level is low add DOT 4 brake fluid only. Maintain the fluid level 6 mm below the top edge of the master cylinder.
Do not overfill. Position the vehicle on a Full level surface. View the fluid level in the master cylinder. Maintain the fluid level between the minimum and maximum marks. The handlebar brake is also hydraulic. Both brake systems are self-adjusting. Brake Inspections Perform the following checks to keep the brake systems in good operat- ing condition.
Page Toe Alignment Stands and rear of the front rim. Rear measure- ment should be mm more than the front measurement.
If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Handlebar Adjustment The handlebars can be adjusted for rider preference. Remove the seat. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. Pull the panel downward and rearward to remove it. Locate the throttle cable adjuster at the handlebar. Squeeze the end of the rub- ber boot and slide it far enough to expose the end of the inline cable adjuster.
Boot 3. All service must be performed by your authorized Polaris dealer. Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they've been loos- ened for maintenance service. Install wheels properly. Loosen the wheel nuts slightly. Place a suitable stand under the footrest frame to raise the wheel slightly off the ground. Remove the left side panel. Remove the hose clamps from the filter and pull the filter out of the hoses.
The headlight should be approximately 7. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. Lights become dirty during normal operation. Wash the headlights and taillights frequently. Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.
Rotate the taillight socket counterclockwise to remove it. Remove the lamp. Apply dielectric grease to the socket. Install the new lamp. Test the lamp for proper operation. Open the tailgate. Screws 2. Remove the two screws near the tailgate latch. Grasp the entire taillight assembly and pull it away from the vehicle. Remove the harness connector from the back of the light assem- bly.
Torque spark plugs to specification. Remove the spark plug cap. Use the spark plug wrench to remove the spark plug. Turn the plug counterclockwise to remove it. Inspect the electrodes for wear and carbon buildup. If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Engage the starter for only seconds. Dry the spark plug.
Reinstall the plug or install a new plug. Torque to specification. Purge the spark arrestor. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas.
If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear protective gloves. Lightly tap on the exhaust pipe with a rubber mallet while repeat- ing step 5. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. See your dealer as outlined in the owner's manual. Do not install it in any other product. Dry it out before operating. Allow the water to drain completely.
Rein- stall the drain plug. Drain the housing before storing the vehicle. Make sure the housing is completely dry before reinstalling the drain plug. Recoil Housing 1. Page Misc. There are exceptions in the steering, suspension, and engine areas.
Always consult the exploded views in each manual section for torque values of fasteners before using standard torque. Chain Pitch: Distance between chain link pins No. Polaris measures chain length in number of pitches. Crankshaft Run-Out: Run-out or "bend" of crankshaft measured with a dial indicator while crankshaft is supported between centers on V blocks or resting in crankcase.
Page Maintenance If oil level begins to rise, discontinue use and determine cause. NOTE: Inspection may reveal the need for replacement parts. Always use genuine Polaris parts.
Page 24 Inspect level; change yearly if equipped Transmission oil 25 H Monthly Inspect level; change yearly Perform these procedures more often for vehicles subjected to severe use.
Page 25 Inspect routing, condition Valve clearance H 12 M Inspect; adjust Perform these procedures more often for vehicles subjected to severe use. Page 26 Inspect periodically; adjust when parts are replaced Auxiliary brake Inspect daily; adjust as needed Headlight aim Adjust as needed Perform these procedures more often for vehicles subjected to severe use.
Page Lubrication Components 2 Annually or hours of operation refer to Maintenance Schedule for additional information More often under severe conditions operating in water or hauling heavy loads 3 Grease conforming to NLGI No. Page Transmission Lubrication Clean around the drain plug and remove the drain plug and wipe the magnetic end clean to remove all accumulated metallic filings.
AW ISO 10 hydraulic fluid equivalent. Locate bleeder valves found on either side of differential Shifter and remove the protective caps. Throttle lever operation should be smooth and lever Slide boot off throttle cable adjuster and jam nut.
Verify system pressure has been relieved before disassembly. Compression readings will vary in proportion to cranking speed during the test. Average compression measured is about psi EFI Example during a compression test.
Page Spark Plug Check the level and verify it removed. Page Liquid Cooling System Overview Overheating of engine could occur if air is not fully purged from system. Do or radiator fitting may distort, not dilute with water. NOTE: When clear and open. Slip the pre-filter element off of main element. Clean the Proper placement of the air filter is important to prevent rattles and air leaks.
The in-line filter is similar in appearance to a fuel filter, and is visible on the left side Location A. In-line breather filters can be installed in either direction. To check the oil level: Set machine on a level surface. Page 44 Remove dipstick and fill tank with 2 quarts 1. Place gear selector in Park and set parking brake. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the Inspect and adjust valve clearance while the engine is cold and dipstick.
Page Intake Valve Clearance Adjustment Check routing of all cables, hoses, and wiring to be sure Repeat this step for the other intake valve. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine Polaris parts. Set handlebars in a straight ahead position and secure handlebars in this position.
This will tell you which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie rod s need adjustment. This brake should not stop the wheels from Pads should be changed when the friction material is worn to turning until the lever is half way between its rest position. Shock Spanner Wrench Brake control and switch must be positioned to allow brake lever to travel throughout entire range without contacting switch PN body.
Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation. To open the maneuverability. IN pulls the cable into the winch and OUT feeds the cable out of the winch. This information is for Sportsman models equipped with a winch in the front. Turn the fuel valve off and drain the carburetor bowl only. Polaris does not recommend the use of a high pressure type car wash system for washing the ATV.
If a high pressure system is Page 57 If Polaris fuel system additive is not used, fuel tank, and fuel lines should be completely drained of gasoline. Lubricate Inspect all cables and lubricate with Polaris Cable Lubricant. If the piston has an identification mark, follow the directions for piston placement below.
Remove recovery bottle hose from coolant filler. The system must Never remove radiator cap when engine is warm or hot.
Never substitute or mix oil brands. Page Electrical Rinse thoroughly, dry with compressed air, and oil To correct a situation like the one shown in the illustration, the bore immediately with Polaris 2 Cycle Lubricant. Here it passes through the slotted friction bearing 0W Synthetic Engine Hot located in the stator plate into the crankshaft. The plunger should move Inspect each rocker arm cam follower surface. If there is smoothly in and out of the tensioner body.
NOTE: Always inspect camshaft lobe if rocker arms are Release ratchet pawl and push inward on plunger. Remove camshaft end cap and O-Ring. Rocker Shaft Oil Clearance: Std:. NOTE: The automatic compression release mechanism can be inspected and serviced without removing the camshaft from Sprocket Teeth the cylinder head. The actuator ball C in the camshaft is not replaceable. Visually inspect each cam lobe for wear, chafing or Apply engine oil to release lever shaft.
Thoroughly clean the cam shaft, making sure the oil feed The actuator ball must be held outward to allow installation holes are not obstructed. Compare to specifications. Remove the two 6mm flange bolts A from cylinder head. Journal O. D See next exploded view on next page. NOTE: Keep all parts in order with respect to their location in the cylinder head. Thoroughly clean cylinder head A surface to remove all traces of gasket material and carbon. Check seat area B. NOTE: The valves cannot be re-faced or end spring for squareness.
Replace ground. Valves must be replaced if worn, bent, or damaged. Head temperature can be checked with a pyrometer or a welding temperature stick. Valve Guide Installed Height Place 46 cutter on the pilot and make a light cut. Valve Guide Height: The valve seat should contact the middle of the valve face or slightly normal condition.
The valve seats should hold fluid with no seepage. Wear eye protection during assembly. NOTE: Follow engine disassembly procedures to remove valve cover, camshaft and rocker arms, and cylinder head. Do not scratch the ring lands. Remove circlip. Note piston directional arrow pointing Repeat procedure for second ring. Remove piston circlip and push piston pin out of piston. Subtract this measurement from the maximum cylinder measurement obtained in Step 5 above.
Feeler Gauge mm Cylinder Measure piston pin O. Piston Ring Measure connecting rod small end ID. Measure in two directions 90 Remove recoil housing bolts and remove housing. Calculate bushing clearance. Replace if worn past service limit. Chain Service Limit: 5. NOTE: The crankshaft slotted nut is a left-hand thread.
Remove cam chain drive sprocket and woodruff key from crankshaft. Remove flange bolts 10 from magneto side crankcase Remove three oil pump retaining bolts and pump. Inspect mating surface of crankcase and oil pump. Check Separate crankcase by tapping with a soft faced hammer in for nicks, burrs, or surface irregularities.
Clean and dry all parts thoroughly. Apply clean engine oil to all parts. Do not use gasket sealer on the pump body mating surfaces or oil passages will become plugged. Install pump shaft and scavenge rotor drive pin. Be careful not to damage the crankcase crankcase. Use a feeler gauge to measure the connecting rod big end Inspect the balancer drive gear and pump shaft drive gear. Replace the pump shaft seal and water pump mechanical seal whenever the crankcase is disassembled.
Place the bearings in a freezer. Subtract the Crankshaft Width measured in Step 7 from the surface to the main bearing using the same method and Total Case Width recorded in Step 6, and record below.
Measure the distance from the Mag crankcase mating Install the gear on the oil pump and measure the width of surface to the balance shaft bearing using a dial caliper and the pump and gear.
Subtract this measurement from the a straight edge. Install the crankshaft into the PTO side crankcase. Be sure the alignment pins are in place. Water Pump Mechanical Seal Set the crankcase in position carefully to avoid damaging Puller: PN the pump shaft seal, and install the magneto end crankshaft installation tool follow instructions provided with the The tab must be positioned in the notch on the Install the Woodruff key, drive sprocket, and slotted nut.
Tighten the nut to the specified torque. Place the dowel pins in the crankcase and install a new Remove all traces of old gasket material. Apply clean engine oil liberally to the cylinder bore and The following procedure must be used to torque the cylinder head properly: tapered area of the sleeve. Install the cylinder with a slight rocking motion until the rings are captive in the sleeve. When the cam to the camshaft main journals and cam lobes.
Cam Sprocket Bolt Torque: 6 ft. Release the ratchet pawl A and push the tensioner plunger B all the way into the tensioner body. Install the stator plate being careful not to damage the seal. Inspect plate friction spring for wear, damage, and proper tension. The spring should fit tightly on friction plate. A face shield and eye protection is required during this procedure. Replace any parts found to be worn or damaged.
Install reel into housing making sure the spring drive tab on the reel engages the spring and the reel is fully seated in the housing. Gasoline powered engine exhaust fumes are poisonous and can cause loss of consciousness Polaris EFI Diagnostic Software and death in a short time. Page Polaris EFI systems. Polaris Dealers can order special tools from SPX.
Fuel Injector 7. Fuel Rail 8. Squeeze Connector Tabs 4. Route the clear hose into a portable Fuel Pump gasoline container or the equipment fuel tank. Reinstall the tank assembly. NOTE: A small amount of fuel may come out of the Reconnect the sender wiring harness and route the harness fuel line or tank. The fuel injector mounts into the intake manifold, and the fuel rail attaches at the top end. Replaceable O-Rings on both ends of the injector prevent external fuel leakage and also insulate it EFI Engines use a non-serviceable, high-volume, high- from heat and vibration.
Refer to the EFI Diagnostic 0. Software Manual for more information. Verify that the 9 volt battery is new. Mounted on the cylinder, the engine temperature sensor measures coolant temperature. Carbon Clean stabilizes the fuel, or 89 Oxygenated preventing clogging of the small passages and orifices common to ATV carburetors, and ensures constant performance, reliability and easier starting.
The lines must be free of kinks, restrictions and be properly routed. This allows fuel to flow in Main Main Main Raising or lowering the slide increases or decreases the cross sectional This system supplies fuel during engine operation with throttle area in the venturi, and therefore the air velocity in the venturi valve closed 1 or slightly opened. Consequently the passage, through a screen on the back of the inlet needle seat 4 , vacuum slide 2 moves upward.
Fuel Flow throttle valve closed or slightly opened. Fuel Flow The jet needle has five adjustment grooves cut into the upper In a full throttle condition the cross sectioned area between the portion, and is tapered from approximately the middle of the jet needle and the needle jet is larger than the cross sectioned needle to the lower end. Upon disassembly, and float pin can be removed.
Remove inlet needle seat retaining screw along with plate, and carefully remove needle seat. Replace diaphragm assembly if diaphragm is damaged. Inspect jet needle and needle jet for wear.
Look for discoloration, shiny spots, or an area that looks different than the rest of the needle. Refer to Page 2. When measuring the height, be sure the inlet needle valve spring is not compressed. Be sure to re—attach the bowl drain hose after performing the test.
A fuel level test allows you to observe the height of the fuel in the float bowl without removing the carburetor. The pump is located under the left front fender of the machine. Fuel Pump Testing To test the fuel pump: Turn fuel off. Disconnect impulse line from pump. Inspect the diaphragms for cracks, holes or swelling. Disconnect the negative battery cable.
Remove the side panels and front cab assembly. Press inside insert A until it snaps into place. Step 3 Side Panel Removal Side panel removal is quick and easy, use the following instructions for removal and installation. Remove seat by releasing the latch and lifting up on the seat. Front Storage Remove Bolts Remove the two T25 screws that secure the storage box to the front fender well areas each side.
Pull the tabs out of the notches and lift up on the cover piece. Remove the two screws B that secure the front cab to the frame in the fuel tank mount area. Install rear rack onto rear frame and cab. Lift the rear cab from the frame. The bottom handle bar block has a side with 3 holes, the side with 3 holes faces up and to the front of the ATV.
Align the pin A in the top block with the middle hole B in the bottom block for proper installation. Ball Joint Stud Bushing 8 ft. Apply grease to extension cap and threads of puller bolt to NOTE: Refer to the illustration on the previous page ease removal. Front Strut Cartridge Replacement Remove the handle bar pod. NOTE: Refer to illustration on following page. Remove the handle bar.
Remove the fuel tank bracket assembly. Hold strut rod and remove top nut. Sign In OR. Don't have an account? Sign up! Restore password. Upload manual. Upload from disk.
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