Polaris Outlaw 450 MXR User Manual

6IntroductionSafety Words and SymbolsThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved

96MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Fuel Usedin gallons (liters)E Compression

97MaintenancePeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe useE Emission-Related ServiceQ Have an a

98MaintenanceEngine Oil RecommendationsAlways check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on

99MaintenanceEngine Oil LevelCheck the oil level before each use of the vehi-cle. If the engine is cold, the oil level should be visible at the lower

100MaintenanceEngine Oil ChangeAlways change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 87. Change the oil

101MaintenanceEngine Oil Change1. Position the vehicle on a level surface.2. Start the engine. Allow it to idle for two to three minutes. Stop the eng

102MaintenanceEngine Oil ChangeCleaning the Short Oil ScreenShort ScreenShort Oil Screen PlugView from bottom of vehicleFrontO-Rings

103MaintenanceEngine Oil ChangeCleaning the Short Oil Screen1. Remove the short oil screen plug at the bottom of the engine.2. Remove the short oil sc

104MaintenanceEngine Oil ChangeCleaning the Long Oil Screen1. Remove the long screen plug, located on the side of the engine near the engine number.2.

105MaintenanceEngine Oil ChangeCleaning the Long Oil Screen5. Insert the tool through the opening and into the bore of the opposite engine casing wall

7IntroductionFailure to follow the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not

106MaintenanceEngine Oil ChangeChanging Oil Filters1. Place a drain pan under the engine.2. Remove the four oil filter cover screws (1). Remove the co

107MaintenanceEngine Oil ChangeChanging Oil Filters6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. Tighten screws to 4

108MaintenanceEngine Cooling SystemThe engine coolant level is controlled or maintained by the recovery system. The recovery system components are the

109MaintenanceEngine Cooling SystemCoolant LevelThe recovery bottle is located on the right side of the vehicle under the front fender. If the fluid l

110MaintenanceEngine Cooling SystemRadiator Coolant LevelIf the recovery bottle has run dry, inspect the level in the radiator and add coolant if nece

111MaintenanceEngine Cooling SystemCooling System BleedingBleeding the cooling system is required only if the system has been drained for maintenance

112MaintenanceAir Filter Systems1. Remove the seat.2. Release the airbox cover clips and remove the cover.3. Remove the wing nuts securing the filter

113MaintenanceCarburetorNormal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and

114MaintenanceCarburetorCarburetor DrainingDrain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on pa

115MaintenanceCarburetor JettingCarburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be

8IntroductionVehicle Identification NumbersRecord your vehicle's identification numbers and key number in the spaces provided. Remove the spare k

116MaintenanceLightsHeadlight Adjustment1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall.2.

117MaintenanceLightsHeadlight Adjustment4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2"

118MaintenanceLightsHeadlight Lamp ReplacementWhen servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a re

119MaintenanceLightsHeadlight Assembly Replacement1. Remove the front cover.2. Remove the wire harness connector from the headlight.3. Remove the two

120MaintenanceFront Cab/Side Panel RemovalThe front cab and side panel assembly is removed in one piece.1. Remove the seat.2. Remove the two front cov

121MaintenanceRear Cab Removal1. Remove the seat.2. Remove the two lower bolts (1) on the rear fenders of the cab.3. Remove the two bolts and grommets

122MaintenanceSpark PlugsRefer to the specifications section beginning on page 168 for recommended spark plug type and gap.NOTICE: Using non-recommend

123MaintenanceSpark PlugsNormal PlugThe normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are no

124MaintenanceSpark Arrestor Clean-OutFailure to heed the following warnings while servicing the spark arrestor could result in serious injury or deat

125MaintenanceSpark Arrestor Clean-OutTo remove accumulated carbon, clean the spark arrestor at the intervals recommended in the Periodic Maintenance

9IntroductionVehicle Identification NumbersVehicle Model Number: ________________________________________________________________________Frame Vehicle

126MaintenanceVehicle ImmersionIf the vehicle tips or overturns in water deeper than the footpeg level, or if the engine stops during or after operati

127MaintenanceVehicle Immersion1. Turn the fuel valve off.2. Drain water from the air box and clean the air filter. See page 112.3. Drain the carburet

128MaintenanceVehicle Immersion6. Press and hold the starter button for 10 second intervals for about one minute or until water vapor is no longer eje

129MaintenanceBatteryImproperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing

130MaintenanceBattery StorageWhenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that i

131MaintenanceBattery InstallationAlways install a fully charged battery. Using a new battery that has not been fully charged can damage the battery a

132MaintenanceBattery Charging (Sealed Battery)On a sealed battery, the sealing strip cannot be removed. Use a voltmeter or multimeter to measure DC v

133MaintenanceBattery Charging (Sealed Battery)The Polaris Battery Tender battery charger can be left connected during the storage period and will aut

134MaintenanceBattery Charging (Sealed Battery)Always verify battery condition before and 1-2 hours after the end of charging.State of ChargeVoltage A

135MaintenanceTiresOperating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle

10SafetySafety TrainingATV safety training is a top priority for Polaris. Polaris strongly encourages you and any family members who will be riding th

136MaintenanceWheel Nut Torque SpecificationsCheck the wheel nut torques occasionally and when they've been loosened for maintenance.Wheel Hub Ti

137MaintenanceWheel Installation1. Place the transmission in gear. Lock the parking brake.2. Place the wheel on the wheel hub with the valve stem towa

138MaintenanceClutch System BleedingAlways bleed the clutch system at the intervals out-lined in the Periodic Maintenance Chart beginning on page 87.

139MaintenanceClutch System Bleeding4. Remove the bleeder screw (2) from the slave cylinder. 5. Press fluid into the system until the fluid runs out o

140MaintenanceThrottle Lever FreeplayPeriodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm).If ad

141MaintenanceThrottle Cable Freeplay AdjustmentImproper adjustment of throttle cable freeplay can result in loss of control, which could result in se

142MaintenanceBrakesUnder normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm

143MaintenanceBrakes1. Always maintain brake fluid at the recommended level. See pages 48-49. 2. Check the brake system for fluid leaks.3. Check the b

144MaintenanceToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting.WA

145MaintenanceToe Alignment3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush

11SafetySafety TrainingA Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehic

146MaintenanceChain Tension InspectionCheck the amount of chain slack by moving the vehicle slightly forward to remove slack at the top side of the ch

147MaintenanceChain Tension Inspection1. Collapse the suspension with an adjustable (buckle type) trailer tie down strap (1). Fas-ten the strap around

148MaintenanceChain Tension Adjustment1. Loosen the two eccentric locking bolts. Refer to the illustration on the following page.2. Insert a pin punch

149MaintenanceChain Tension AdjustmentStep 1Step 2Proper splicelink clip opening position

150MaintenanceHandlebar AdjustmentImproper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited

151MaintenanceSteering InspectionCheck the steering assembly periodically for loose nuts and bolts. If loose nuts and bolts are found, or if you notic

152MaintenanceSuspension SettingsUse a flat-blade screwdriver to make damping adjustments. When the adjuster screw is turned clockwise until it stops,

153MaintenanceFront SuspensionCompression Damping (Limited Edition)To adjust the front suspension compression damping, use the adjustment procedures o

154MaintenanceFront SuspensionSpring Preload1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully exten

155MaintenanceRear SuspensionThe rear suspension spring preload, shock rebound damping and shock compression damping may be adjusted to suit different

12SafetyEquipment ModificationsWe are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that cons

156MaintenanceRear SuspensionRebound DampingUse a flat-blade screwdriver to make damping adjustments. The rebound damping is factory set at 16 clicks

157MaintenanceRear SuspensionCompression DampingUse a flat-blade screwdriver to make damping adjust-ments. The factory setting is at 10 clicks from fu

158MaintenanceCleaningKeeping your vehicle clean will not only improve its appearance but it can also extend the life of various components.NOTICE: Hi

159MaintenanceCleaningWashing the VehicleWashing Tips• Avoid the use of harsh cleaners, which can scratch the finish.• Do not use a power washer to cl

160MaintenanceCleaningWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water m

161MaintenancePolishingPolaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follo

162MaintenanceStorageNOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur.

163MaintenanceStorageEngine OilChange the oil and both filters. Clean the oil screens. See page 100.Air Filter / Air BoxInspect and clean (or replace)

164MaintenanceStorageStabilize the Fuel1. Fill the fuel tank with fuel.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow t

165MaintenanceStorageLubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-tenance Chart beginning on

13SafetySafe Riding GearAlways wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce t

166MaintenanceTransporting the ATV1. Stop the engine.2. Place the transmission in first gear.3. Lock the parking brake.4. Remove the key to prevent lo

167MaintenanceTransporting the ATV

168SpecificationsOUTLAW 450 MXRMax. Weight Capacity 215 lbs./98 kg Pilot Jet #45Dry Weight 360 lbs./163 kg Main Jet #138Fuel Capacity 3.1 gal./11.8 l

169SpecificationsOUTLAW 450 MXR Jetting ChartOUTLAW 450 MXRDriving System Type Rear Two-Wheel Drive Tire Size - Front 20 x 6R10Shift Type 5-Speed Manu

170SpecificationsOUTLAW 525 SMax. Weight Capacity 215 lbs./98 kg Pilot Jet #45Dry Weight 370 lbs./168 kg Main Jet #138Fuel Capacity 3.1 gal./11.8 l Cl

171SpecificationsOUTLAW 525 S Jetting ChartOUTLAW 525 SDriving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10Shift Type 5-Speed Manual S

172Polaris ProductsPart Number DescriptionEngine Lubricant2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)2876245 PS-4 PLUS Performance

173Polaris ProductsPart Number DescriptionCoolant2871323 60/40 Coolant (gal.)2871534 60/40 Coolant (qt.)Additives / Miscellaneous2871326 Carbon Clean

174TroubleshootingSee your Polaris dealer if you're unable to identify solutions using the following charts.Engine Turns Over, Fails to StartPoss

175TroubleshootingEngine Turns Over, Fails to StartPossible Cause SolutionNo spark to spark plug Inspect, clean and/or replace spark plugsSee your Pol

14SafetySafe Riding GearEye ProtectionDo not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear sha

176TroubleshootingEngine Doesn’t Turn OverEngine Pings or KnocksPossible Cause SolutionFuseable link See Polaris dealer for replacementLow battery vol

177TroubleshootingEngine BackfiresPossible Cause SolutionWeak, fouled or defective spark plug Inspect, clean and/or replace spark plugsIncorrect spark

178TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionFouled or defective spark plug Inspect, clean and/or replace spark

179TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionClogged air filter Inspect and clean or replaceElectronic throttle

180TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Lean Fuel Mixture Cause SolutionLow or contaminated fuel Add or change fuel, cle

181TroubleshootingEngine Fails to Reach High RPMEngine Uses Excessive OilPossible Cause SolutionWorn or dirty needle valve Clean and/or replace needle

182TroubleshootingEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn the fuel valve to reserve, refuelInterrupted fuel supply Clean fu

183TroubleshootingEngine Stops or Loses PowerPossible Cause SolutionKinked or plugged fuel vent line Inspect and replaceWater present in fuel Replace

184TroubleshootingEngine OverheatsPossible Cause SolutionDebris lodged in radiator screen Remove and clean the screenPlugged radiator Use a garden hos

185TroubleshootingEngine Fails to Reach Full PowerPossible Cause SolutionInterrupted fuel supply Clean fuel system and carburetorFloat leaks Replace t

15SafetySafety WarningsFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serio

186Declaration of ConformityPolaris Industries Inc., 2100 Hwy 55, Medina, MN 55340 U.S.A.Telephone 763-542-0500We, Polaris Industries Inc., declare th

187Declaration of ConformityPRODUCT IDENTIFICATIONVEHICLE SERIES TRADE NAME MODELYEARSSOUNDPRESSUREdB (A)___KA05__ OUTLAW 50 2008, 2009, 2010 76.8___K

188Declaration of ConformityVEHICLE SERIES TRADE NAME MODELYEARSSOUNDPRESSUREdB (A)___MN76__ SPORTSMAN 800 2008, 2009, 2010 83.6___TN85__, ___DN85__ S

189WarrantyLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris

190WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

191WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESWarranty applies to the product only and does not allow for coverage

192WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThis warranty also excludes failures resulting from improper lubrica

193WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WAR

194WarrantyHOW TO OBTAIN WARRANTY SERVICEIf your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs

195WarrantyEXPORTED VEHICLESEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-LETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

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

16SafetySafety WarningsOperating Without InstructionOperating this ATV without proper instruction increases the risk of an accident. The operator must

196WarrantyEXPORTED VEHICLESHow to Get ServiceIf You Move:If you move to another country, be sure to contact Polaris Customer Assistance and the custo

197WarrantyU.S.A. EPA Emissions Limited WarrantyThis emissions limited warranty is in addition to the Polaris standard limited warranty for your vehic

198WarrantyU.S.A. EPA Emissions Limited WarrantyFor exhaust emissions, emission-related components include any engine parts related to the following s

199WarrantyU.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris,

200WarrantyU.S.A. EPA Emissions Limited WarrantyThis limited warranty excludes failures not caused by a defect in material or workmanship.This limited

201Maintenance LogPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

202Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS6090

203Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS

204Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS

205IndexAAge Restrictions . . . . . . . . . . . . . . 15Air Filter Systems . . . . . . . . . . . . 112BBatteryCharging. . . . . . . . . . . . 132

17SafetySafety WarningsHandling GasolineGasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution wheneve

206IndexFFluidBrake . . . . . . . . . . . . . . . . 48-49Clutch . . . . . . . . . . . . . . . . . . 43Foot Brake . . . . . . . . . . . . . . . . .

207IndexRRebound Damping, Rear. . . . . . . 156Restrictions, Age. . . . . . . . . . . . . . 15Reverse Lock-Out Switch . . . . . . . 54Riding Are

208IndexSSpark Arrestor Clean-Out. . . 124-125Spark Plugs. . . . . . . . . . . . . . 122-123Spring Preload . . . . . . . . . . . . . . . 153Spring

18SafetySafety WarningsFailure to Inspect Before OperatingFailure to inspect and verify that the ATV is in safe operating condition before operating i

19SafetySafety WarningsCarrying a PassengerCarrying a passenger greatly reduces the operator's ability to balance and control the ATV, which may

20SafetySafety WarningsOperating on PavementOperating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely

21SafetySafety WarningsOperating at Excessive SpeedsOperating the ATV at excessive speeds increases the operator's risk of losing control. Always

22SafetySafety WarningsTurning ImproperlyTurning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper

23SafetySafety WarningsImproper Hill ClimbingImproper hill climbing could cause loss of control or overturn. Always follow proper procedures for climb

24SafetySafety WarningsDescending Hills ImproperlyImproperly descending a hill could cause loss of control or overturn.• Always follow proper procedur

25SafetySafety WarningsCrossing HillsidesDriving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid c

The text is printed on 100% recycled with 40% post-consumer waste (PCW).

26SafetySafety WarningsStalling While Climbing a HillStalling, rolling backwards or improperly dismounting while climbing a hill could cause an overtu

27SafetySafety WarningsOperating on Slippery TerrainFailure to use extra caution when operating on excessively rough, slippery or loose terrain could

28SafetySafety WarningsOperating in Unfamiliar TerrainFailure to use extra caution when operating on unfamiliar terrain could result in an accident or

29SafetySafety WarningsImproper Vehicle ModificationsImproper installation of accessories or modification of the ATV may cause changes in handling, wh

30SafetySafety WarningsOperating Through Deep WaterOperating the ATV through deep or fast-flowing water could cause the tires to float, causing loss o

31SafetySafety WarningsPoor VisibilityOperating the ATV in darkness or inclement weather could result in a collision or accident, especially if operat

32SafetySafety WarningsOperating on Frozen Bodies of WaterOperating on frozen bodies of water may result in serious injury or death if the ATV and/or

33SafetySafety WarningsHot Exhaust SystemsExhaust system components are very hot during and after use of the vehicle. Hot components can cause burns a

34SafetySafety Labels and LocationsWarning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label

35SafetySafety Labels and LocationsGeneral WarningWARNINGImproper ATV use can result in SEVERE INJURY OR DEATH.Always use an approved helmet and prote

WARNINGImproper ATV use can result in SEVERE INJURY or DEATH.READ OWNER'S MANUAL. FOLLOWALL INSTRUCTIONS AND WARNINGS.ALWAYS USEAN APPROVEDHELMET

36SafetySafety Labels and LocationsAge 16 WarningWARNINGOperating this ATV if you are under the age of 16 increases your chance of severe injury or de

37SafetySafety Labels and LocationsNo Passenger WarningWARNINGNEVER ride as a passenger.Passengers can cause a loss of control, resulting in SEVERE IN

38Features and ControlsStart ButtonEngineStop SwitchMain Key Switch

39Features and ControlsMain Key SwitchThe main key switch must be in the RUN position to start the engine. See page 66 for starting procedures.Start B

40Features and ControlsLightsIndicator LightsAn illuminated light in the indicator window will alert you to the follow-ing conditions.• Hot engine• Re

41Features and ControlsLightsHeadlightsUse the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The

42Features and ControlsClutch LeverThe hydraulic clutch lever is located on the left handlebar. Squeeze the clutch lever toward the handlebar to disen

43Features and ControlsClutch FluidThe clutch fluid master cylinder is located on the left handlebar. Check the fluid level in the reservoir before ea

44Features and ControlsThrottle LeverOperating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or

45Features and ControlsThrottle LeverThe throttle lever is located on the right handlebar. Squeeze the lever toward the handlebar to increase engine s

1Visit us at www.polarisindustries.com

46Features and ControlsFoot BrakeThe foot brake operates the rear brakes. The brake pedal is located in front of the right-hand footpeg. If the rear w

47Features and ControlsHand BrakeThe hand brake operates the front brakes. The hand brake is located on the right handlebar. These brakes are hydrauli

48Features and ControlsMaster Cylinder/Brake FluidAn over-full master cylinder may cause brake drag or brake lock-up, which could result in an acciden

49Features and ControlsMaster Cylinder/Brake FluidCheck the brake fluid in the master cylinder before each ride. If the fluid level is low add DOT 4 b

50Features and ControlsParking Brake1. Place the transmission in first gear.2. Squeeze and release the brake lever two or three times, then squeeze an

51Features and ControlsParking BrakeThe parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Alwa

52Features and ControlsManual ShiftShift PedalThe gear shift pedal is located in front of the left-hand footpeg. One full stroke of the pedal shifts t

53Features and ControlsManual ShiftShifting GearsAlways allow a cold engine to warm up before shifting gears.1. When starting from a stopped position,

54Features and ControlsManual ShiftReverse Lock-Out SwitchThe reverse lock-out switch prevents the operator from shifting into reverse uninten-tionall

55Features and ControlsManual ShiftDecelerationTo slow or stop the vehicle, release the throttle lever and apply the brakes smoothly and evenly. As th

2POLARIS, THE WAY OUT and OUTLAW are registered trademarks of Polaris Industries Inc.Copyright 2009 Polaris Sales Inc. All information contained withi

56Features and ControlsChokeThe choke assists in starting a cold engine. The choke knob is located on the left side of the carburetor. Refer to the en

57Features and ControlsFuel ValveThe fuel valve is located on the right side of the ATV. It has three positions:OFF: For vehicle storage and when tran

58OperationFailure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or

59OperationBreak-In PeriodPerform the following break-in and maintenance procedures carefully.1. Fill the fuel tank with gasoline. Always exercise ext

60OperationPre-Ride InspectionFailure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an acci

61OperationPre-Ride InspectionPre-Ride Checklist PageCoolant (if applicable) Ensure proper level 109Coolant hoses (if applicable) Inspect for leaks --

62OperationSafe Operation Practices1. Complete the recommended safety training before operating this vehicle. See page 10.2. Do not allow anyone under

63OperationSafe Operation Practices8. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never

64OperationKnow Your Riding Area/Tread LightlyFamiliarize yourself with all laws and regulations concerning the operation of this off-road vehicle in

65OperationTrail EtiquetteAlways practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the s

3WelcomeThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

66OperationStarting the EngineThe engine can be started when the transmission is in neutral, or while in gear if the clutch is disengaged. If starting

67OperationStarting the Engine5. Move the engine stop switch to the RUN position. Turn the ignition key to ON.6. If starting the engine while in gear,

68OperationDriving Procedures1. Wear a helmet and eye protection.2. Sit upright with both feet on the footpegs and both hands on the handlebars.3. Sta

69OperationMaking TurnsYour ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. The wheel on the outside of th

70OperationDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow the

71OperationDriving on Slippery Surfaces4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid

72OperationDriving UphillBraking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or

73OperationDriving Uphill5. Keep both feet on the footpegs.6. Shift body weight uphill.7. Proceed at a steady rate of speed and throttle opening. Open

74OperationDriving on a Sidehill (Sidehilling)Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Av

75OperationTurning Around on a HillIf the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around:1. Keep you

4WelcomeWe believe Polaris sets a standard of excellence for all utility and recreational vehicles man-ufactured in the world today. Many years of exp

76OperationTurning Around on a Hill7. With the front brakes applied, pull in the clutch lever. Use the brakes to slowly allow the vehicle to roll arou

77OperationTurning Around on a Hill9. Pull in the clutch lever, shift into neutral and restart the engine.10. Release the parking brake and slowly rel

78OperationDriving DownhillWhen driving downhill, follow these precautions:1. Avoid steep hills (25° maximum).2. Shift body weight uphill. Transfer yo

79OperationParking on a Hill or InclineAvoid parking on an incline if possible. If it's unavoidable, follow these precau-tions:1. Stop the engine

80OperationDriving Through WaterPolaris does not recommend operating in water deeper than the height of the footpegs. Follow these precautions when op

81OperationDriving Through WaterNOTICE: Serious engine damage can result if the vehicle is not thoroughly inspected after operating in water deeper th

82OperationDriving in ReverseFollow these precautions when operat-ing in reverse:1. Always check for obstacles or peo-ple behind the vehicle.2. Always

83OperationDriving in Reverse7. Do not operate at full throttle. Use just enough throttle to maintain a desired speed.8. Always look left, right and b

84OperationDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before oper-ating in a new area.

85Emission Control SystemsNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

5Table of ContentsIntroduction. . . . . . . . . . . . . . . . . . 6Safety . . . . . . . . . . . . . . . . . . . . . 10Features and Controls . . . .

86Emission Control SystemsExhaust Emission Control SystemThe emissions from the exhaust of this vehicle are controlled by engine design, including fac

87MaintenancePeriodic Maintenance ChartRoutine inspection and service are critical to the performance and reliability of your high performance engine.

88MaintenancePeriodic Maintenance ChartThe recommended service intervals are based on average riding conditions. Vehicles sub-jected to severe use mus

89MaintenancePeriodic Maintenance ChartImproperly performing the procedures marked with a Q could result in component failure and cause an accident, w

90MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksSeePageHours Calendar Fuel UsedBrake systems/brake fluid

91MaintenancePeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe useE Emission-Related ServiceQ Have an a

92MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksSeePageHours Calendar Fuel Usedin gallons (liters)Brake

93MaintenancePeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe useE Emission-Related ServiceQ Have an a

94MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Fuel Usedin gallons (liters)Xz Upper stee

95MaintenancePeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe useE Emission-Related ServiceQ Have an a