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WARNING The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner’s manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-342-3764 for assistance.
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We’vecreatedawebsitejust for YOU! S Technicaltips S Newproductintroductions S Eventschedules S PartsandServiceManualinformation S Excitingdetails aboutThe WayOut Checkit out... www.polarisindustries.com/owner 1
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Copyright2003PolarisSalesInc.Allinformationcontainedwithinthispublicationis basedonthelatestproductinformationatthetimeofpublication. Duetoconstant improvementsinthedesignandqualityofproductioncomponents,someminor discrepanciesmay resultbetween theactualvehicleand theinformation presented in this publication. Depictionsand/orproceduresinthispublicationareintendedforreference useonly.No liability can beaccepted foromissionsorinaccuracies. Any reprinting or reuseofthedepictionsand/orprocedurescont
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WELCOME ThankyouforpurchasingaPolaris vehicle, andwelcometoour world-widefamilyofPolaris owners. Weproudlyproduceanexciting lineofutilityandrecreational products. PolarisRecreationalVehicles S Snowmobiles S All-terrainvehicles(ATVs) S Watercraft S RANGERutilityvehicles S Victory motorcycles PolarisProfessionalSeriesWorkmobilest S UtilityTaskVehiclest(UTVs) S Personal Task Vehiclest(PTVs) S All-SurfaceLoaders (ASLs) WebelievePolaris sets astandardofexcellenceforall utilityand recreational vehicle
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VEHICLEIDENTIFICATIONNUMBERS Theframevehicleidentificationnumber(VIN)andengineserial numberareimportant formodel identificationwhenregisteringyour vehicle, when obtaining insurance, and when ordering replacement parts. Intheevent yourvehicleis stolen, thesenumbers areessential to therecoveryandidentificationofyourvehicle. Removethesparekey and storeit in asafeplace. Yourkey can be duplicatedonlybymatingaPolaris keyblankwithoneofyour existingkeys. Ifbothkeys arelost, theignitionswitchmust be repl
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TABLEOFCONTENTS WELCOME........................................ 3 VEHICLEIDENTIFICATION NUMBERS............... 4 SAFETY .......................................... 6 FEATURESAND CONTROLS ...................... 32 OPERATION ..................................... 47 EMISSION CONTROL SYSTEMS ................... 64 MAINTENANCEAND LUBRICATION ................ 65 TROUBLESHOOTING ............................ 103 POLARISPRODUCTS............................ 105 SPECIFICATIONS...............................
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SAFETY SafetyDecalsandLocations Warning decals havebeen placed on theATVforyourprotection. Read and followtheinstructions ofthedecals on theATVcarefully. Ifany ofthedecals depicted in this manual differfrom thedecals on your ATV, always read and followtheinstructions ofthedecals ontheATV. Ifany decal becomesillegibleorcomes off, contact yourPolaris dealer to purchaseareplacement. Replacementsafetydecals areprovided by Polaris at no charge. Thepart numberis printed on thedecal. WARNING WARNING Op
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SAFETY SafetyDecalsandLocations WARNING IMPROPERTIRE PRESSURE OROVERLOADINGcan cause loss of control resulting in SEVERE INJURY ORDEATH. TIRE PRESSURE INPSI(KPa): FRONT5 (34,5) REAR 5 (34,5) MAXIMUM WEIGHTCAPACITY (Gross Vehicle Weight) INCLUDINGMACHINE, DRIVER AND CARGOIS 1200 LBS. (545 kg). Reduce speed and allow greaterdistance forbraking when carrying cargo. Overloading orcarrying tall, off-center, orunsecured loads will increase yourrisk of losing control. Loads should be centered, carrieda
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SAFETY SafetyDecalsandLocations WARNING Movingparts hazardunderbelt-clutchguard.To preventserious injury,donotoperatevehiclewith guardremoved. Donotmodify engineor clutch.Doingsocancause partfailure,possibleimbalance,andexcessiveengine RPMwhichcanresultinserious injury or death. 7078689 NOSTEP WARNING S DONOTTOWFROMRACKORBUMPER. Vehicledamageortipovermay resultcausingsevereinjury ordeath.Towonly fromtowhooks orhitch. S Max Rack Loads:Front100lbs.(45kg) Rear 200lbs.(91kg) 7170912 8
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SAFETY SafetyDecalsandLocations WARNING MANUFACTURED ALLWHEEL Pushing reverse BY:POLARIS IND.INC. DRIVE override button SWITCH may cause DATE: sudden in- VIN: creases in pow- Do not push switch to erand traction if engageAWDiftherear too much THISVEHICLEISANALLTERRAINVEHICLEANDISNOT wheels are spinning. throttle is ap- INTENDEDFORUSEONPUBLICROADS. Thismaycausesevere plied. Loss of drive shaft and clutch control orfor- CEVÉHICULEESTUN VÉHICULETOUTTERRAIN QUINiEST ward flipover damage. PASDESTINÉÀ
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SAFETY SafeRidingGear Always wearclothingsuitedtothetypeofriding. ATVridingrequires special protectiveclothingforcomfort andtoreducethechanceof injury. 1.Helmet Yourhelmet is themost important piece ofprotectivegearforsaferiding. A helmet can prevent aseverehead injury. 1 Select an approved helmet that meets orexceeds yourstate’s safety standards and bears eithertheDepartment of Transportation (DOT)label, the AmericanNational Standards Institutelabel (ANSIz90.1), orthe 2 Snell Memorial Foundatio
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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 Thefollowingsignal words andsymbols appearthroughout this manual andonyourvehicle. Yoursafetyis involvedwhenthesewords andsymbols areused. Becomefamiliarwiththeirmeanings before readingthemanual. The safety alert symbol, on your vehicle 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 that
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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 Readthis manual andall labels carefully, andfollowtheoperating procedures described. S NeveroperateanATVwithout properinstruction. Takeatraining course. Beginners should receivetraining from acertified instructor. Contact an authorized Polaris ATVdealerorcall Polaris at 1-800-342-3764tofindout about thetrainin
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SAFETY Operator Safety S Always havetheATVinspected by an authorized Polaris dealerif it’s been involved in an accident. S Neveroperateonhills toosteepfortheATVorforyourabilities. Practiceonsmallerhillsbeforeattemptinglargerhills. S Always followproperprocedures forclimbinghills. Checktheter- raincarefullybeforeascendingahill. Neverclimbhillswithexces- sively slippery orloosesurfaces. Shift yourweight forward. Never openthethrottlesuddenlyormakesuddengearchanges. Nevergo overthetopofahill at hig
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SAFETY Operator Safety S Wet brakes mayhavereducedstoppingability. Test thebrakes after leavingwater. Ifnecessary, applythem lightlyseveral times toallow friction to dry out thepads. S Always checkforobstacles orpeoplebehindtheATVbeforeoperat- ing in reverse. When it’s safeto proceed in reverse, moveslowly andavoidturningat sharpangles. S Always usethesizeandtypeoftires specifiedforyourATV, and always maintainpropertirepressure. S Nevermodify an ATVthrough improperinstallation oruseofacces- sori
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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. WARNING POTENTIAL HAZARD Operating an ATV on
