Polaris Outlaw 9922079 User Manual

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Summary of Contents

Page 2

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

Page 3 - The engine exhaust from this

97MaintenanceEngine Oil LevelCheck the oil level before each use of the vehicle. If the engine is cold, the oil level should be visible at the lower e

Page 4

98MaintenanceEngine Oil ChangeAlways change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Change the oil m

Page 5

99MaintenanceEngine Oil Change1. Position the vehicle on a level surface.2. Remove the skid plate for better access to the oil drain plug and short sc

Page 6

100MaintenanceEngine Oil ChangeCleaning the Short Oil ScreenShort ScreenShort Oil Screen PlugView from bottom of vehicleFrontO-Rings

Page 7

101MaintenanceEngine Oil ChangeCleaning the Short Oil Screen1. Remove the short oil screen plug at the bottom of the engine. See illustration on prece

Page 8 - Table of Contents

102MaintenanceEngine Oil ChangeCleaning the Long Oil Screen1. Remove the long screen plug, located on the side of the engine near the engine number.2.

Page 9

103MaintenanceEngine Oil ChangeCleaning the Long Oil Screen5. Insert the tool through the opening and into the bore of the opposite engine casing wall

Page 10 - Introduction

104MaintenanceEngine Oil ChangeChanging Oil Filters1. Place a drain pan under the engine.2. Remove the four oil filter cover screws (1). Remove the co

Page 11

105MaintenanceEngine Oil ChangeChanging Oil Filters6. Grease the filter cover O-rings (3). 7. Reinstall the covers and the screws. Tighten screws to 4

Page 12

106MaintenanceEngine Cooling SystemThe engine coolant level is controlled or maintained by the recovery system. The recovery system components are the

Page 13 - Safety Training

8IntroductionService RequirementsThe high performance engine in your vehicle requires routine service to maintain the highest level of performance and

Page 14

107MaintenanceEngine Cooling SystemCoolant LevelThe recovery bottle is located on the right side of the vehicle under the front fender. If the fluid l

Page 15 - Equipment Modifications

108MaintenanceEngine Cooling SystemRadiator Coolant LevelIf the recovery bottle has run dry, inspect the level in the radiator and add coolant if nece

Page 16 - Safe Riding Gear

109MaintenanceEngine Cooling SystemCooling System BleedingBleeding the cooling system is required only if the system has been drained for maintenance

Page 17

110MaintenanceAir Filter SystemsRefer to the illustrations on page 111.1. Remove the seat.2. Release the airbox cover clips and remove the cover.3. Lo

Page 18 - Safety Warnings

111MaintenanceAir Filter SystemsStep 3 Step 5Step 4Step 7Step 6

Page 19

112MaintenanceCarburetorNormal wear from engine vibrations may cause the carburetor to supply an overly rich fuel mixture. Replace the jet needle and

Page 20

113MaintenanceCarburetorCarburetor DrainingDrain the carburetor float bowl at the intervals outlined in the Periodic Maintenance Chart beginning on pa

Page 21

114MaintenanceCarburetor JettingCarburetor re-jetting can be performed to compensate for altitude and/or temperature changes. If the vehicle is to be

Page 22

115MaintenanceLightsHeadlight Adjustment1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a flat wall.2.

Page 23

116MaintenanceLights4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be aimed 2" (5 cm) below the mar

Page 24

9IntroductionVehicle Identification NumbersVehicle Model Number: ____________________________________________________________________Frame Vehicle Ide

Page 25

117MaintenanceLightsHeadlight Lamp ReplacementWhen servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a re

Page 26

118MaintenanceLightsHeadlight Assembly Replacement1. Remove the front cover.2. Remove the wire harness connector from the headlights.3. Remove the two

Page 27

119MaintenanceLightsBrake Light AdjustmentCheck the rear brake light for proper operation before each use of the vehicle.1. Turn the ignition key on.2

Page 28

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

Page 29

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

Page 30

122MaintenanceSpark PlugsRefer to the specifications section beginning on page 168 for recommended spark plug type and gapNOTICE: Using non-recommende

Page 31

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

Page 32

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

Page 33

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

Page 34

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

Page 35

10SafetySafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorize

Page 36

127MaintenanceVehicle Immersion1. Turn the fuel valve off.2. Drain water from the air box and clean the air filter. See page 110.3. Drain the carburet

Page 37 - Safety Labels and Locations

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

Page 38

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

Page 39

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

Page 40

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

Page 41 - Features and Controls

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

Page 42

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

Page 43

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

Page 44

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

Page 45

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

Page 46

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

Page 47

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

Page 48

138MaintenanceBoot InspectionBefore OperatingInspect the boots before operating the vehicle. If a boot is torn, punctured or leaking fluid, see your P

Page 49

139MaintenanceBoot Burping1. Using a needle nose pliers or boot clamp removal tool, remove the small boot clamp (1) from the inboard boot. Do not use

Page 50

140MaintenanceClutch System BleedingAlways bleed the clutch system at the intervals out-lined in the Periodic Maintenance Chart beginning on page 85.

Page 51

141MaintenanceClutch System Bleeding4. Remove the bleeder screw (2) from the slave cylinder. 5. Press fluid into the system until the fluid runs out o

Page 52

142MaintenanceThrottle Lever FreeplayPeriodically check throttle lever freeplay. Maintain freeplay between 1/16" and 1/8" (1.5 - 3 mm).If ad

Page 53

143MaintenanceThrottle Cable Freeplay AdjustmentImproper adjustment of throttle cable freeplay can result in loss of control, which could result in se

Page 54

144MaintenanceBrakesUnder normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm

Page 55

145MaintenanceBrakes1. Always maintain brake fluid at the recommended level. See pages 48-49. 2. Check the brake system for fluid leaks.3. Check the b

Page 56

146MaintenanceToe AlignmentUse the following procedure to check the toe alignment of the vehicle. The vehicle is designed for a neutral toe setting.WA

Page 57

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

Page 58

147MaintenanceToe Alignment4. Measure the distance between the marks and record the measurement (1).5. Move the vehicle until the chalk marks are at t

Page 59

148MaintenanceChain TensionCAUTION! Never adjust or operate the vehicle with the rear drive chain too loose or too tight. Severe damage to the transmi

Page 60

149MaintenanceChain Tension3. Tighten the pivot mounting bolts to 30 ft. lbs. (40 Nm).4. Torque the chain adjusting bolt to 17 ft. lbs. (23 Nm).5. Che

Page 61 - Operation

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

Page 62

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

Page 63

152MaintenanceFront SuspensionSuspension Set-Up1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the front of the vehicle by pl

Page 64

153MaintenanceFront SuspensionSuspension Set-Up6. Place the transmission in neutral and slowly roll the machine forward and rearward at least ten feet

Page 65

154MaintenanceFront SuspensionSpring PreloadThe front suspension preload may be adjusted to suit different riding conditions and operator weight.WARNI

Page 66

155MaintenanceFront SuspensionSpring Preload1. Raise and safely support the front of the vehicle off the ground to allow the suspension to fully exten

Page 67

156MaintenanceRear SuspensionSuspension Set-Up1. Position the vehicle on a level surface.2. Stop the engine.3. Elevate the rear of the vehicle by plac

Page 68

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

Page 69

157MaintenanceRear SuspensionSuspension Set-Up5. Remove the stand and have a rider sit comfortably on the seat with hands on the handle-bars.6. Place

Page 70

158MaintenanceRear SuspensionThe rear suspension spring preload and shock compression damping may be adjusted to suit different riding conditions and

Page 71

159MaintenanceRear SuspensionCompression DampingThe compression damping clickers are located on the bottom of the shocks (on the lower clevis). Use a

Page 72

160MaintenanceCleaningKeeping your vehicle clean will not only improve its appearance but it can also extend the life of various components.NOTICE: Hi

Page 73

161MaintenanceCleaningWashing the VehicleWashing Tips• Avoid the use of harsh cleaners, which can scratch the finish.• Do not use a power washer to cl

Page 74

162MaintenanceCleaningWashing the VehicleIf a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water m

Page 75

163MaintenancePolishingPolaris recommends the use of common household aerosol furniture polish for polishing the finish on your Polaris vehicle. Follo

Page 76

164MaintenanceStorageEngine OilChange the oil and both filters. Clean the oil screens. See page 98.Air Filter / Air BoxInspect and clean (or replace)

Page 77

165MaintenanceStorageStabilize the Fuel1. Fill the fuel tank with fuel.2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Follow t

Page 78

166MaintenanceStorageLubricateInspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Main-tenance Chart beginning on

Page 79

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

Page 80

167MaintenanceTransporting the ATVFollow these procedures when transporting the vehicle.1. Stop the engine.2. Place the transmission in first gear.3.

Page 81

168SpecificationsOutlaw 525 IRSMax. Weight Capacity 215 lbs./97.5 kg Pilot Jet 45Dry Weight 389 lbs./176 kg Main Jet 148Fuel Capacity 3.1 gal./11.7 l

Page 82

169SpecificationsJetting ChartOutlaw 525 IRSDriving System Type Rear Two-Wheel Drive Tire Size - Front 21 x 7R10Shift Type 5-Speed Manual Shift Tire S

Page 83

170Polaris ProductsPart Number DescriptionEngine Lubricant2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)2876245 PS-4 PLUS Performance

Page 84

171Polaris ProductsPart Number DescriptionCoolant2871323 60/40 Coolant (gal.)2871534 60/40 Coolant (qt.)Additives / Miscellaneous2871326 Carbon Clean

Page 85

172TroubleshootingSee your Polaris dealer if you're unable to identify solutions using the following charts.Engine Turns Over, Fails to StartPoss

Page 86 - Emission Control Systems

173TroubleshootingEngine Turns Over, Fails to StartPossible Cause SolutionNo spark to spark plug Inspect, clean and/or replace spark plugsSee your Pol

Page 87

174TroubleshootingEngine Doesn’t Turn OverEngine Pings or KnocksPossible Cause SolutionFuseable link See Polaris dealer for replacementLow battery vol

Page 88

175TroubleshootingEngine BackfiresPossible Cause SolutionWeak, fouled or defective spark plug Inspect, clean and/or replace spark plugsIncorrect spark

Page 89

176TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionFouled or defective spark plug Inspect, clean and/or replace spark

Page 90

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

Page 91

177TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionClogged air filter Inspect and clean or replaceElectronic throttle

Page 92

178TroubleshootingEngine Runs Irregularly, Stalls or MisfiresPossible Lean Fuel Mixture Cause SolutionLow or contaminated fuel Add or change fuel, cle

Page 93

179TroubleshootingEngine Fails to Reach High RPMEngine Uses Excessive OilPossible Cause SolutionWorn or dirty needle valve Clean and/or replace needle

Page 94

180TroubleshootingEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn the fuel valve to reserve, refuelInterrupted fuel supply Clean fu

Page 95

181TroubleshootingEngine Stops or Loses PowerPossible Cause SolutionKinked or plugged fuel vent line Inspect and replaceWater present in fuel Replace

Page 96

182TroubleshootingEngine OverheatsPossible Cause SolutionDebris lodged in screen Remove and clean the screenPlugged radiator Use a garden hose to flus

Page 97

183TroubleshootingEngine Fails to Reach Full PowerPossible Cause SolutionInterrupted fuel supply Clean fuel system and carburetorFloat leaks Replace t

Page 98

184WarrantyLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris

Page 99

185WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESThe Polaris limited warranty excludes any failures that are not caus

Page 100 - Maintenance

186WarrantyWARRANTY COVERAGE AND EXCLUSIONS:LIMITATIONS OF WARRANTIES AND REMEDIESALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WAR

Page 101

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

Page 102

187WarrantyHOW TO OBTAIN WARRANTY SERVICEIf your ATV requires warranty service, you must take it to a Polaris dealer authorized to repair Polaris ATVs

Page 103

188WarrantyEXPORTED VEHICLESEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BUL-LETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

Page 104

189WarrantyEXPORTED VEHICLESHow to Get ServiceIn the country where your vehicle was purchased:Warranty or Service Bulletin repairs must be done by an

Page 105

190WarrantyEXPORTED VEHICLESHow to Get ServiceIf Purchased From A Private Party:If you purchase a Polaris product from a private citizen outside of th

Page 106

191WarrantyU.S.A. EPA Emissions Limited WarrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in add

Page 107

192WarrantyU.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris,

Page 108

193Maintenance LogPresent this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with

Page 109

194Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS6090

Page 110

195Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS

Page 111

196Maintenance LogDATE SERVICE INTERVAL(HOURS)TECHNICIAN SERVICE PERFORMED / COMMENTS

Page 113

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

Page 114

197IndexAAge Restrictions . . . . . . . . . . . . . . 15Air Filter Systems . . . . . . . . . 110-111BBatteryCharging . . . . . . . . . . . . . 13

Page 115

198IndexFFluidBrake . . . . . . . . . . . . . . . . . . 48-49Clutch . . . . . . . . . . . . . . . . . . . . 43Foot Brake . . . . . . . . . . . . .

Page 116

199IndexPParking Brake . . . . . . . . . . . . . . 50-51Parking on a Hill or Incline. . . . . . 78Passenger Warning . . . . . . . . . . . . 37Per

Page 117

200IndexSSide Panel Removal . . . . . . . . . . . 120Sidehilling . . . . . . . . . . . . . . . . . . . 74Signal words . . . . . . . . . . . . . . .

Page 118

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

Page 119

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

Page 120

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

Page 121

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

Page 122

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

Page 123

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

Page 124

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

Page 125

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

Page 126

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

Page 127

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

Page 128

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

Page 129

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

Page 130

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

Page 131

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

Page 132

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

Page 133

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

Page 134

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

Page 135

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

Page 136

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

Page 137

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

Page 138

1Visit us at www.polarisindustries.com

Page 139

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

Page 140

38Features and ControlsStart ButtonEngineStop SwitchMain Key Switch

Page 141

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

Page 142

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

Page 143

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

Page 144

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

Page 145

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

Page 146

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

Page 147

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

Page 148

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

Page 149

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.Copyright 2008 Polaris Sales Inc. All information contained withi

Page 150

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

Page 151

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

Page 152

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

Page 153

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

Page 154

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

Page 155

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

Page 156

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

Page 157

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

Page 158

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

Page 159

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

Page 160

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

Page 161

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

Page 162

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

Page 163

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

Page 164

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

Page 165

61OperationPre-Ride InspectionPre-Ride Checklist PageCoolant (if applicable) Ensure proper level 107Coolant hoses (if applicable) Inspect for leaks --

Page 166

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

Page 167

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

Page 168

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

Page 169

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

Page 170

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

Page 171 - Specifications

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

Page 172

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,

Page 173 - Polaris Products

68OperationDriving Procedure1. Wear a helmet and eye protection.2. Sit upright with both feet on the footpegs and both hands on the handlebars.3. Star

Page 174

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

Page 175 - Troubleshooting

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

Page 176

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

Page 177

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

Page 178

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

Page 179

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

Page 180

75OperationDriving DownhillWhenever descending a hill, follow these precautions:1. Avoid steep hills (25° maximum).2. Shift body weight uphill. Transf

Page 181

76OperationTurning 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

Page 182

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

Page 183

77OperationTurning 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

Page 184

78OperationParking on a Hill or InclineAvoid parking on a hill or incline if pos-sible. If it's unavoidable, follow these precautions:1. Turn the

Page 185

79OperationDriving Over ObstaclesFollow these precautions when operating over obstacles:1. Always check for obstacles before oper-ating in a new area.

Page 186

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

Page 187 - Warranty

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

Page 188

82OperationDriving in ReverseFollow these precautions when operating in reverse:1. Always check for obstacles or people behind the vehicle.2. Always a

Page 189

83Emission Control SystemsNoise Emission Control SystemDo not modify the engine, intake or exhaust components, as doing so may affect compliance with

Page 190

84Emission Control SystemsExhaust Emission Control SystemThe emissions from the exhaust of this vehicle are controlled by engine design, including fac

Page 191

85MaintenancePeriodic Maintenance ChartThe high performance engine in your vehicle requires routine service to maintain the highest level of performan

Page 192

86MaintenancePeriodic Maintenance ChartThe recommended service intervals are based on average riding conditions. Vehicles sub-jected to severe use mus

Page 193

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

Page 194

87MaintenancePeriodic Maintenance ChartImproperly performing the procedures marked with a Q could result in component failure and cause an accident, w

Page 195

88MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksSeePageHours Calendar Fuel UsedBrake systems/brake fluid

Page 196 - Maintenance Log

89MaintenancePeriodic Maintenance ChartX Perform these procedures more often for vehicles subjected to severe useE Emission-Related ServiceQ Have an a

Page 197

90MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksSeePageHours Calendar Fuel Usedin gallons (liters)Brake

Page 198

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

Page 199

92MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Fuel Usedin gallons (liters)Xz Upper stee

Page 200

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

Page 201

94MaintenancePeriodic Maintenance ChartItem Maintenance Interval(whichever comes first)RemarksHours Calendar Fuel Usedin gallons (liters)E Compression

Page 202

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

Page 203

96MaintenanceEngine Oil RecommendationsAlways check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on

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