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2003
ATV
Universal
Owner's Manual
for
Vehicle Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
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WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.
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We’vecreated aweb sitejust for YOU! S Technicaltips S New productintroductions S Eventschedules S PartsandServiceManualinformation S Excitingdetails aboutThe WayOut Checkit out... www.polarisindustries.com/owner 1
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Allinformationinthismanualisbasedonthelatestproductdataandspecifications availableatthetimeofprinting.PolarisIndustriesInc.reservestherighttomakeproduct changesand improvementsthatmay affectillustrationsorexplanations. Nopartofthismanualshallbereproducedorusedwithoutthewritten permission of PolarisIndustriesInc. Copyright2002 PolarisIndustriesInc. AllRightsReserved PrintedintheU.S.A. 2
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WELCOME Thank you forpurchasing aPolaris vehicle, and welcometo our world-widefamily ofPolaris owners. Weproudly producean exciting lineofutility and recreational products. Polaris Recreational and Utility Vehicles S Snowmobiles S All-terrainvehicles (ATVs) S Personal watercraft S Victory motorcycles S RANGERutilityvehicles Polaris Professional Series Workmobilest S UtilityTaskVehiclest(UTVs) S Personal Task Vehiclest(PTVs) S All-SurfaceLoaders (ASLs) WebelievePolaris sets astandard ofexcellence
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TABLEOF CONTENTS WELCOME................................. 3 TABLE OFCONTENTS ...................... 5 VEHICLE IDENTIFICATION NUMBERS........ 6 SAFETY ................................... 7 CONTROLS ............................... 37 FEATURES ............................... 48 OPERATION .............................. 56 NOISE EMISSION CONTROL SYSTEMREGULATION.................. 74 MAINTENANCE AND LUBRICATION......... 75 POLARIS RECOMMENDED PRODUCTS .... 141 TROUBLESHOOTING ..................... 142
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VEHICLEIDENTIFICATIONNUMBERS Thevehicleframevehicleidentification number(VIN)(1)and engine serial number(2)areimportant formodel identification when registering yourvehicle, when obtaining insurance, and when ordering replacement parts. Ifyourvehicleis stolen, thesenumbers areessential to therecovery and identification ofyourvehicle. Removethesparekey and storeit in asafeplace. Yourkey can be duplicated only by mating aPolaris key blank with oneofyour existing keys. Ifboth keys arelost, theignit
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SAFETY Operator Safety WARNING Failure to follow the warnings contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions. Read and understand your owner’s manual and all warnings before o
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SAFETY Operator Safety Thefollowing signal words and symbols appearthroughout this manual and on yourATV. Yoursafety is involved when thesewords andsymbols areused. Becomefamiliarwith theirmeanings before reading themanual. The safety alert symbol, on your ATV or in this manual, alerts you to the potential for personal injury. WARNING 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 tha
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SAFETY Operator Safety WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner’s manual. S Read this manual and all labels carefully, and followtheoperating procedures described. S Neveroperatean ATVwithout properinstruction. Takea training course. Beginners should receivetraining from acertified instructor. Contact an authorized Polaris ATV dealerorcall Polaris at 1-800-342-3764 to find out about t
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SAFETY Operator Safety S Always havetheATV inspected by an authorized Polaris dealerif it’s been involved in an accident. S Neveroperateon hills too steep fortheATVorforyourabilities. Practiceonsmallerhills beforeattemptinglargerhills. S Always followproperprocedures forclimbing hills. Check theter- raincarefullybeforeascendahill. Neverclimbhills withexcessive- ly slippery orloosesurfaces. Shift yourweight forward. Neveropen thethrottlesuddenly ormakesudden gearchanges. Nevergo over thetop ofahi
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SAFETY Operator Safety S Wet brakes may havereduced stopping ability. Test yourbrakes after leaving water. Ifnecessary, apply them lightly several times to allow friction to dry out thepads. S Always check forobstacles orpeoplebehind theATVbeforeoperat- ing in reverse. When it’s safeto proceed in reverse, moveslowly and avoid turning at sharp angles. S Always usethesizeand typeoftires specified foryourATV, and always maintain propertirepressure. S Nevermodify an ATVthrough improperinstallation o
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOIDTHE HAZARD Beginning and inexperienced operators should complete the certified training course offered by Polaris. Operators should regularly practice the skills learned in the course and the operating technique
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Carrying a passenger on an ATV. WHAT CAN HAPPEN Carrying a passenger greatly reduces the operator’s ability to balance and control the ATV, which could cause an accident and injury to the operator and/or passenger. HOW TO AVOIDTHE HAZARD Never carry a passenger. The purpose of the long seat is to allow the operator to shift position as needed during operation. It is not intended for carrying passengers. 13
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating an ATV on paved surfaces, including sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use. Operating on paved surfaces may seriously affect the handling and control of the ATV and could result in loss of control, accident, and/or injury. HOW TO AVOIDTHE HAZARD Avoid operating the ATV on pavement. If it’s unavoidable, travel slowly and avoid sudden turns or stops. 14
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOIDTHE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it’s illegal to operate ATVs on public streets, roads and highways. 15
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating this ATV without wearing an approved helmet, eye protection and protective clothing. WHAT CAN HAPPEN Operating an ATV without an approved helmet increases the risk of a severe head injury or death in the event of an accident. Operating without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident. HOW TO AVOIDTHE HAZARD Always wear an approved helmet that fits properly. Alw
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOIDTHE HAZARD Never consume alcohol or drugs before or while operating an ATV. WARNING POT
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SAFETY Operator Safety WARNING POTENTIAL HAZARD Attempting wheelies, jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOIDTHE HAZARD Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving. 18
