Polaris Outlaw User Manual

7VEHICLE IDENTIFICATION NUMBERSVehicle Model Number:Frame VIN (1)(left side):Engine Serial Number (2)(right side):Key Number (3):

97MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)Brake systems/fl

98MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)" Steering

99MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)"EAir filte

100MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)Carburetor floa

101MAINTENANCE AND LUBRICATIONPeriodic Mainten an ce ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)"FUpper

102MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)Coolant strengt

103MAINTENANCE AND LUBRICATIONPeriodic Maintenance ChartItemMaintenance Interval(whichever comes first)RemarksHours Calendar Miles (Km)Radiator 100 H

104MAINTENANCE AND LUBRICATIONLubrication RecommendationsPerformance Synthetic 4 -Stroke (PS-4) OilPolaris highly recommends the use of Polari s PS-4

105MAINTENANCE AND LUBRICATIONEngine Oil L evelCheck the oil level before each use of the vehicle.The dipstick (1) is located on the left side of the

106MAINTENANCE AND LUBRICATIONEngine Oil L evelIf the ATV is used year-round, check the oil level frequently. A rising oil level couldindicate the acc

8SAFETYSafety Decals and Lo catio n sWarning decals have been placed on the ATV for your protection. Read and follow theinstructions of the decals on

107MAINTENANCE AND LUBRICATIONOil an d Filter ChangeCAUTIONIf the ATV is left without oil in the system for extended periods, the oil pump may loseits

108MAINTENANCE AND LUBRICATIONOil an d Filter Change1. Position t he vehicle on a level surface.2. Clean the area around the oil tank (1) andcrankcase

109MAINTENANCE AND LUBRICATIONOil an d Filter Change7. Place a drain pan beneath t he crankcase and remove the drain plug.8. Allow the oil to drain co

110MAINTENANCE AND LUBRICATIONOil an d Filter Change14. Replace the o-ring in the cover.15. Lubricate the gasket on the new filter with a film of fres

111MAINTENANCE AND LUBRICATIONOil an d Filter Change18. Remove the dipstick and fill the oil tank with the recommended oil.19. Place the t ransmission

112MAINTENANCE AND LUBRICATIONOil Pump PrimingThis priming procedure m ust be performed whenever theoil hose connection between the oil tank and pump

113MAINTENANCE AND LUBRICATIONEngine Cooling SystemThe engine coolant level is controlled or maintained by the recovery system. The recoverysystem com

114MAINTENANCE AND LUBRICATIONEngine Cooling SystemCoolant LevelThe recovery bottle (1) is located on the right side of thevehicle under the front fen

115MAINTENANCE AND LUBRICATIONEngine Cooling SystemWARNINGEscaping steam can cause severe burns. Never remove the pressure cap while theengine is warm

116MAINTENANCE AND LUBRICATIONAir F ilter Systems1. Unlatch and remove the seat.2. Release the two airbox cover clips (1)and rotat e the cover rearwar

9SAFETYSafety Decals and Lo catio n sLocation BLocation C7172560E1997, 2000IF OWNER’S MANUAL IS MISSING, CO NTACTA POLARIS DEALER FOR A REPLACEMENT.WA

117MAINTENANCE AND LUBRICATIONAir F ilter Systems9. Wash the main filter element (4) without removing it from the internal filter cage. Rinseand let d

118MAINTENANCE AND LUBRICATIONLightsWhen servicing a halogen lamp, don’t t ouch the lamp with bare fingers. Oil from your skinleaves a residue, causin

119MAINTENANCE AND LUBRICATIONLightsHeadlight Lamp Replacement1. Remove the wire harness connector from theback of the headlight.2. On the left headla

120MAINTENANCE AND LUBRICATIONLightsHeadlight Assembly Replacement1. Remove the wire harness connector from theheadlights.2. Remove the front cab (see

121MAINTENANCE AND LUBRICATIONLightsHeadlight Assembly Replacement5. Install the new headlamp by inserting the outboard pivot pin in the hole of themo

122MAINTENANCE AND LUBRICATIONLightsHeadlight Adjustment1. Position the ATV on a level surface with the headlightapproximately 25 ft. (7.6 m) from a f

123MAINTENANCE AND LUBRICATIONFront Cab Removal1. Remove the screws (1) from the left and right cabmounts.2. Remove the wire harness connector from th

124MAINTENANCE AND LUBRICATIONRear Cab Removal1. Unlatch and remove the seat.2. Remove the two lower bolts (1) on the rearfenders of the cab and the t

125MAINTENANCE AND LUBRICATIONSpark PlugsS Use NGK DCPR8E spark plugs.S Proper electrode gap is .035″ (.90 mm).S Spark plug torque is 14 ft. lbs. (19

126MAINTENANCE AND LUBRICATIONSpark Plugs1. NormalThe normal insulator tip is gray, tan or light brown. There will be few combustiondeposits. The elec

10SAFETYSafety Decals and Lo catio n sEDFLocation FHGI7172566WARNINGLocation E

127MAINTENANCE AND LUBRICATIONSpark PlugsSpark Plug Removal and Replacement1. Remove the side panels and front cab (see page 123).2. Turn the fuel val

128MAINTENANCE AND LUBRICATIONSpark PlugsSpark Plug Removal and Replacement3. Move the fuel valve hose clamp (1) forward and gently remove the hose fr

129MAINTENANCE AND LUBRICATIONSpark PlugsSpark Plug Removal and Replacement5. Remove the tank mounting bolt (3) at the rear of the gas tank.6. Move th

130MAINTENANCE AND LUBRICATIONSpark Arrestor Clean-OutWARNINGDo not perform clean-out immediately after the engine has been run, as the exhaustsystem

131MAINTENANCE AND LUBRICATIONSpark Arrestor Clean-OutPeriodically clean the spark arrestor to removeaccumulated carbon.1. Remove the three screws (1)

132MAINTENANCE AND LUBRICATIONVehicle ImmersionIf your ATV has been submerged or overturned in water deeper than the footpeg level, it’scritical to dr

133MAINTENANCE AND LUBRICATIONVehicle Immersion1. Turn the fuel valve off.2. Drain water from the air box and clean the air filter (if equipped). See

134MAINTENANCE AND LUBRICATIONVehicle Immersion6. Press and hold the starter button for 10 second intervals for about one minute or untilwater vapor i

135MAINTENANCE AND LUBRICATIONBatteryThe sealed battery is already filled with elect rolyte and has been sealed and fully charged atthe factory. Never

136MAINTENANCE AND LUBRICATIONBattery StorageWhen the vehicle is placed in storage for three months or more, the battery should beremoved and stored o

11SAFETYSafety Decals and Lo catio n sATTENTIONS Operation of this v ehicle without the air filterelement will severely damage the engine.S Clean pre-

137MAINTENANCE AND LUBRICATIONBattery Installation1. Place the battery in the battery holder.2. Connect and tighten the red (positive) cable first, th

138MAINTENANCE AND LUBRICATIONBattery Charging (Sealed Battery)The battery included with your ATV is sealed and the sealing strip cannot be removed. U

139MAINTENANCE AND LUBRICATIONBattery Charging (Sealed Battery)NOTE: Always verify battery condition before and 1-2 hours after charging.State ofCharg

140MAINTENANCE AND LUBRICATIONTiresWARNINGOperating your ATV with worn tires, improperly inflated tires, non-standard tires orimproperly installed tir

141MAINTENANCE AND LUBRICATIONTire Tread DepthAlways replace tires when tread depth is worn to1/8″ (.3 cm) or less. See illustration.Wheel Removal1. S

142MAINTENANCE AND LUBRICATIONWheel Installatio nWARNINGImproperly installed wheels can adversely affect tire wear and vehicle handling, whichcan resu

143MAINTENANCE AND LUBRICATIONWheel Nut Torque SpecificationsCheck the wheel nut torques occasionally and when they’ve been loosened for maintenancese

144MAINTENANCE AND LUBRICATIONBoot InspectionBefore OperatingInspect the boots before operating the vehicle. If aboot is torn, punctured or leaking fl

145MAINTENANCE AND LUBRICATIONBoot Burping1. Using a needle nose pliers or boot clamp removaltool, remove the small boot clamp (1) from theinboard boo

146ADJUSTMENTSBrakesUnder normal operation, the diaphragm extends into the reservoir as fluid level drops. Ifthe fluid level is low and the diaphragm

E40510390006.03112SAFETYSafe Riding GearAlways wear clothing suited t o the type of riding. ATV riding requires protective clothingfor comfort and to

147ADJUSTMENTSBrakes1. Always maintain the brake fluid at an adequate level(see page 58).2. Check the brake system for fluid leaks.3. Check the brakes

148ADJUSTMENTSWARNINGSevere injury or death can result from improper toe alignment and adjustment. Do notattempt to adjust tie rod alignment. All tie

149ADJUSTMENTSToe Alignment4. Ti e an elastic string (2) around the stands, makingsure the string just touches the side surface of therear tires on ea

150ADJUSTMENTSChain TensionCAUTIONNever adjust or operate the vehicle with the rear drive chain too loose or too tight.Severe damage to the transmissi

151ADJUSTMENTSChain Tension1. Loosen the upper and lower pivot mounting bolts (1).2. Thread the chain adjusting bolt (2) inward or outward to adjust c

152ADJUSTMENTSHandlebarsIf desired, the handlebars can be adjusted for rider preference.WARNINGImproper adjustment of the handlebars or incorrect torq

153ADJUSTMENTSSteering AssemblyThe steering assembly of the ATV should be checked periodically for loose nuts and bolts.If loose nuts and bolts are fo

154ADJUSTMENTSFront SuspensionSuspension Set -Up1. Position t he vehicle on a level surface.2. Stop the engine.3. Elevate the front of the vehicle by

155ADJUSTMENTSFront SuspensionSuspension Set -Up6. Place the transmission in neutral and slowly roll the machine forward and rearward atleast t en fee

156ADJUSTMENTSFront SuspensionSpring PreloadThe front suspension preload may be adjusted to suit different riding conditions andoperator weight.WARNIN

13SAFETYSafe Riding Gear2. Eye ProtectionDo not depend on sunglasses for proper eye protection.Wear shatterproof goggles or a shatterproof helmet face

157ADJUSTMENTSFront SuspensionSpring Preload1. Raise and safely support t he front of the ATV off theground to allow the suspension to fully extend.2.

158ADJUSTMENTSRear SuspensionSuspension Set -Up1. Position t he vehicle on a level surface.2. Stop the engine.3. Elevate the rear of the vehicle by pl

159ADJUSTMENTSRear SuspensionSuspension Set -Up5. Remove the stand and have a rider sit comfortably on the seat with hands on thehandlebars.6. Place t

160ADJUSTMENTSRear SuspensionUse a flat blade screwdriver to make damping adjustments.NOTE: When the adjuster screw is turned clockwise until it stops

161ADJUSTMENTSRear SuspensionThe rear suspension spring preload, shock rebound dampingand shock compression damping may be adjusted to suitdifferent r

1AB162ADJUSTMENTSRear SuspensionCompression DampingThe compression damping clickers (1) are locat ed on topof the shocks (under the rear fenders).Use

163ADJUSTMENTSClutch Lever Freeplay1. Measure clutch lever freeplay betweenthe perch and the lever (A). Thisdistance should be 1/8″ -3/16″(3.1 mm - 4.

164ADJUSTMENTSThrottle Cable FreeplayWARNINGImproper adjustment of throttle cable freeplay can result in loss of control, which couldresult in serious

165ADJUSTMENTSCarburetor/Idle RPMIf the engine idle speed is not satisfactory, and all otherconditions are favorable, the carburetor can be adjusted.1

166ADJUSTMENTSCarburetor/Idle RPMCarburetor re-j etting can be perform ed to compensate for altitude and/or temperaturechanges. If the vehicle is to b

14SAFETYOperator SafetyWARNINGFailure to follow the warnings contained in this manual can result in serious injury ordeath.A Polaris ATV is not a toy

167CLEANING AND STORAGENOTE: See page 181 for the part numbers of Polaris products.Cleaning the ATVKeeping your ATV clean will not only improve its ap

168CLEANING AND STORAGEWaxing the ATVYour ATV can be waxed with any non-abrasive automotive paste wax. Avoid the use ofharsh cleaners since they can s

169CLEANING AND STORAGEStorage RecommendationsCAUTIONStarting the engine during the storage period will disturb the protective film created byfogging

170CLEANING AND STORAGEStorage RecommendationsOil and FilterWarm the engine and change the oil and filter. See page 107.Air Filter / A ir B oxInspe ct

171CLEANING AND STORAGEStorage RecommendationsFog the Engine1. Start the engine and allow it to warm up. Turn engine off.2. Unlatch and remove the sea

172CLEANING AND STORAGEStorage RecommendationsInspect and LubricateInspect all cables and lubricate. Follow lubrication guidelines in the Maintenance

173CLEANING AND STORAGETransporting the ATVFollow these procedures when transporting thevehicle.1. Turn off the engine and remove the key toprevent lo

174TROUBLESHOOTINGContact your Polaris dealer for service if you’re unable to identify solutions using thefollowing charts.Engine Doesn’t Turn OverPos

175TROUBLESHOOTINGEngine Turns Over, Fails to StartPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelClogged fuel valve Inspect and

176TROUBLESHOOTINGEngine Pings or KnocksPossible Cause SolutionPoor quality or low octane fuel Replace with recommended fuelIncorrect ignition timing

15SAFETYOperator SafetyOperator RestrictionsThis vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16years of age. This categ

177TROUBLESHOOTINGEngine Runs Irregularly, Stalls or MisfiresPossible Cause SolutionFouled or defective spark plug Inspect, clean and/or replace spark

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

179TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionOut of fuel Turn fuel valve to reserve, refuelKinked or plugged fuel vent line Ins

180TROUBLESHOOTINGEngine Stops or Loses PowerPossible Cause SolutionClogged, dirty or wet air filter Inspect and clean or replaceElectronic throttle c

181POLARIS PRODUCTSPart # Description Part # DescriptionEngine Lubricant Coolant2874414 Performance Synthetic 4-Stroke (PS-4) Oil (qt.) 2871323 60/40

182SPECIFICATIONSOUTLAWGross Vehicle Weight 645 lbs./292 kg Pilot Jet 37.5Fuel Capacity 3.25 gal./12.3 l Main Jet 145Overall Length 71.5 in./182 cm Ne

183SPECIFICATIONSOUTLAWDriving System Type Rear Two-Wheel Drive Tire Size/Pressure - Front 21x7R10/5psiShift Type 5 -Speed Manual Shift Tire Size/Pres

184WARRANTYLIMITED WARRANTYPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on allcomponents of the Polaris A

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

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

16SAFETYSafety TrainingATV safety training is a top priority for Polaris. When you purchased your new ATV, yourdealer instructed you on the authorized

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

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

189WARRANTYExported VehiclesHow to Get ServiceIn the Country where your vehicle was purchased:Warranty or Service Bulletin repairs must be done by an

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

191WARRANTYU.S.A. EPA Emissions Limited W arrantyThis All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in ad

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

193MAINTENANCE LOGPeriodic Maintenan ce RecordUse the following chart to record periodic maintenance.MaintenanceIntervalPerformedServicingDateServicin

194MAINTENANCE LOGPeriodic Maintenan ce RecordMaintenanceIntervalPerformedServicingDateServicingDealeror PersonRemarks

195MAINTENANCE LOGPeriodic Maintenan ce RecordMaintenanceIntervalPerformedServicingDateServicingDealeror PersonRemarks

17SAFETYSafety TrainingA Polaris ATV is an off-road vehicle. Familiarize yourself with all laws and regulationsconcerning the operation of this vehicl

18SAFETYOperator SafetyThe following two pages identify signal words and symbols that appear in this manual.Your safety is involved when these words a

19SAFETYOperator SafetyCAUTIONThe safety alert caution indicates a potential hazard that may result in minor personalinjury or damage to the vehicle.C

20SAFETYOperator SafetyWARNINGSerious injury or death can result if you do not follow these instructions andprocedures, which are outlined in further

21SAFETYOperator SafetyS Never operate an ATV on a public street , road or highway, including a dirt or gravel road.S Never operate an ATV without wea

22SAFETYOperator SafetyS Never operate on excessively rough, slippery, or loose terrain.S Always follow proper turning procedures as described in this

23SAFETYOperator SafetyS Always follow proper procedures for crossing the side of a hill. Avoid hills with exces-sively slippery or loose surfaces. Sh

24SAFETYOperator SafetyS Avoid operating the ATV through deep or fast-flowing water. If it’s unavoidable, travelslowly, balance your weight carefully,

25SAFETYOperator SafetyEquipment ModificationsWe are concerned for the safety of our customers and for the general public. Therefore, westrongly recom

26SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating this ATV without proper instruction.WHAT CAN HAPPEN: The risk of an accident is greatly incr

WARNINGThe engine exhaust from thisproduct contains chemicals knownto cause cancer, birth defects orother reproductive harm.A card containing importan

27SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Failure to follow the skill and experience recommendationsfor this ATV.WHAT CAN HAPPEN: Severe injury

28SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Failure to follow the age recommendations for this ATV.WHAT CAN HAPPEN: Severe injury and/or death cou

29SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Carrying a passenger onan ATV.WHAT CAN HAPPEN: Carrying a passengergreatly reduces the operator’s abil

30SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating an ATV onpaved surfaces, including sidewalks, paths,parking lots, and driveways.WHAT CAN HAP

31SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operatingthis ATV on public streets, roadsor highways.WHAT CAN HAPPEN:TheATVcould collide with another

32SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating this ATVwithout wearing an approved helmet, eyeprotection and protective clothing.WHAT CAN H

33SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating the ATV after consuming alcohol or drugs.WHAT CAN HAPPEN: Consumption of alcohol and/or drug

34SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Attempting wheelies,jumps and other stunts.WHAT CAN HAPPEN: Attempting stuntsincreases the chance of a

35SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Failure to inspect the ATV before operating.Failure to properly maintain the ATV.WHAT CAN HAPPEN: Poor

36SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Removing hands from the handlebars or feet from thefootpegs during operation.WHAT CAN HAPPEN: Removing

1

37SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Failure to useextra caution when operating the ATV onunfamiliar terrain.WHAT CAN HAPPEN: Unfamiliar te

38SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Failure to use extracaution when operating on excessivelyrough, slippery or loose terrain.WHAT CAN HAP

39SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: T urning improperly.WHAT CAN HAPPEN: Improper turns could cause loss of control and lead to acollision

40SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Climbing hillsimproperly.WHAT CAN HAPPEN: Improper hill climbingcould cause loss of control or overtur

41SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: T raveling downhillimproperly.WHAT CAN HAPPEN: Improperly descendinga hill could cause loss of control

42SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Improperly crossinghills and turning on hills.WHAT CAN HAPPEN: Improperly crossing orturning as hills

43SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Stalling, rolling orimproperly dismounting while climbing a hill.WHAT CAN HAPPEN: The vehicle could ov

44SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Improperly operating over obstacles.WHAT CAN HAPPEN: Operating over obstacles could cause loss of cont

45SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating the ATV through deep or fast-flowing water.WHAT CAN HAPPEN: T ires may float, causing loss o

46SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating this ATV with improper tires, or with improper oruneven tire pressure.WHAT CAN HAPPEN: Use o

2Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest productinformation at the time of publicat

47SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating the ATV with improper modifications.WHAT CAN HAPPEN: Improper installation of accessories or

48SAFETYOperator SafetyWARNINGPOTENTIAL HAZARD: Operating on frozen bodies of water .WHAT CAN HAPPEN: Severe injury or death can result if the ATV and

49SAFETYOperator SafetyWARNINGOperating a damaged ATV can result in an accident with serious injury or death. Afterany overturn or accident, have a qu

50FEATURES AND CONTROLSEngine Electrical Switches123

51FEATURES AND CONTROLSEngine Electrical Switches1. Start Button - The start button engages the starter. Alwaysrelease the start button as soon as the

52FEATURES AND CONTROLSInstrumentationAn illuminated light in the indicator window will alert you to the following conditions.1. Hot engine2. Reverse

53FEATURES AND CONTROLSLightsWARNINGOperating the ATV on streets or roads, especially indarkness, could result in an accident and seriousinjury or dea

54FEATURES AND CONTROLSWARNINGOperating an ATV with sticking or improperly operating throttle controls could causean accident and lead to severe injur

55FEATURES AND CONTROLSElectronic Throttle ControlThis ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed toreduce the

56FEATURES AND CONTROLSFoot BrakeThe foot brake (1) operates the rear brakes. It’s located infront of the right-hand footpeg (2).If the rear wheels sl

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

57FEATURES AND CONTROLSBrake LeverThe brake lever operates the front brakes. It’s l ocated on the righthandlebar. Squeeze the brake lever toward the h

58FEATURES AND CONTROLSMaster CylinderThe master cylinder (1) is on theright-hand handlebar. Check the brakefluid level before each ride. The fluidlev

59FEATURES AND CONTROLSMaster CylinderWARNINGOverfilling the master cylinder will result in brake failure. Without room to expand, theexcess fluid wil

60FEATURES AND CONTROLSParking BrakeWARNINGOperating the ATV while the parkingbrake is engaged could result in anaccident and serious injury or death.

61FEATURES AND CONTROLSParking BrakeImportant SafeguardsS The parking brake may relax if left on for a long period of time. Always block the wheelsto

62FEATURES AND CONTROLSFuel TankThe fuel tank filler cap is located directly below t he handlebar. Use either leaded orunleaded gasoline with a minimu

63FEATURES AND CONTROLSFuel ValveThe fuel valve (1) is located on the left side ofthe ATV. It has three positions:OFF: For vehicle storage and whentra

64FEATURES AND CONTROLSChokeThe choke assists in starting a coldengine. The choke knob (1) is locatedon the left side of the vehicle.Refer to the engi

65FEATURES AND CONTROLSManual ShiftShift PedalThe gear shift pedal is located in front of the left-handfootpeg. One full stroke of the pedal shifts th

66FEATURES AND CONTROLSManual ShiftShifting GearsNOTE: Always allow a cold engine to warm up before shifting gears.1. When starting from a stopped pos

4WELCOMEWe believe Polaris sets a standard of excellence for all utility and recreational vehiclesmanufactured in the world today. Many years of exper

67FEATURES AND CONTROLSManual ShiftReverse Lock-Out SwitchThe reverse lock-out switch (1)prevents the operator fromshifting into reverseunintentionall

68FEATURES AND CONTROLSManual ShiftDecelerationTo slow or stop the ATV, release the throttle lever and apply the brakes smoothly andevenly. As the veh

69OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certain conditions.S Always exercise extreme caution whenever handling g

70OPERATIONBreak -In PeriodCareful treatment of a new engine and transmission will result in more efficientperformance and longer life for both. The b

71OPERATIONBreak -In Period1. Fill the fuel tank with gasoline. See page 62.2. Check the oil level on the dipstick. See page 105. Add oil if necessary

72OPERATIONPre-Ride In spectionWARNINGIf a proper inspection is not done before each use, severe injury or death could result.Always inspect the vehic

73OPERATIONPre-Ride In spectionPre-Ride Checklist See PageFrame nuts, bolts, fasteners Inspect, ensure tightness --Fuel and oil Ensure proper levels 1

74OPERATIONStarting a Cold EngineThe engine can be started when t he transmission is in neutral, or while in gear if the clutchis disengaged.WARNINGEn

75OPERATIONStarting a Cold Engine3. Sit on the ATV. Pull the choke knob (1) out until it stops.NOTE: If the knob doesn’t stay where positioned,increas

76OPERATIONStarting a Cold EngineNOTE: If starting the engine while in neutral, the neutral indicator light should be on. If itisn’t, disengage the cl

5TABLE OF CONTENTSVEHICLE IDENTIFICATION NUMBERS 6...SAFETY 8...FEATU

77OPERATIONStarting a Warm EngineFollow the procedure for starting a cold engine, but do not use the choke.If the engine has cooled to a point where i

78OPERATIONDriving SafelyDriving Procedures1. Sit upright with both feet on the footpegs and bothhands on the handlebars.2. Start the engine and allow

79OPERATIONDriving SafelyMaking TurnsYour ATV i s equipped with a solid rear axle, which drives both rearwheels equally at all times. The wheel on the

80OPERATIONDriving SafelyDriving on Slippery SurfacesWhenever riding on slippery surfaces such as wet trails or loosegravel, or during freezing weathe

81OPERATIONDriving SafelyDriving UphillWhenever traveling uphill, follow these precautions:1. Always travel straight uphill.2. Avoid steep hills (25_

82OPERATIONDriving SafelyDriving Across HillsWARNINGImproperly crossing hills or turning on hills can result in loss of control or vehicleoverturn, re

83OPERATIONDriving SafelyDriving DownhillWhenever descending a hill, follow theseprecautions:1. Proceed directly downhill.2. Transfer your weight to t

84OPERATIONDriving SafelyTurning Around on a HillWARNINGImproper hill climbing procedures could cause loss of control or overturn and result inserious

85OPERATIONDriving SafelyTurning Around on a Hill5. Staying uphill of the ATV, turn the handlebars fullleft. Reach across the handlebar and apply thef

86OPERATIONDriving SafelyParkingonanInclineAvoid parking on an incline ifpossible. If it’s unavoidable,follow these precautions:1. Turn the engine off

6VEHICLE IDENTIFICATION NUMBERSRecord your ATV’s identification numbers and key number in the spaces provided.Remove the spare key and store it in a s

87OPERATIONDriving SafelyDriving Over ObstaclesBe alert!Look ahead and learn to read the terrainyou’re traveling on. Be constantly alert forhazards su

88OPERATIONDriving SafelyDriving Through WaterYour ATV can operate through water with amaximum recommended depth equal to thelevel of the footpegs (1)

89OPERATIONDriving SafelyDriving Through WaterCAUTIONMajor engine damage can result if the vehicle is not thoroughly inspected afteroperation in water

90OPERATIONDriving SafelyDriving in ReverseFollow these precautions when operating inreverse:1. Avoid backing downhill.2. Back slowly.3. Apply the bra

91OPERATIONDriving SafelyDriving in ReverseWARNINGFailure to use caution when operating in reverse can result in serious injury or death.Before shifti

92EMISSION CONTROL SYSTEMSNoise Emission Con t rol SystemDo not modify the engine, intake or exhaust components, as doing so may affectcompliance with

93EMISSION CONTROL SYSTEMSCrankcase Emission Control SystemThis engine is equipped with a closed crankcase system. Blow-by gases are forced back tothe

94MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleCareful periodic maintenance will help keep your vehicle in t he safest, most reliablecondit

95MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleSevere Use DefinitionS Frequent immersion in mud, water or sandS Racing or race-style high R

96MAINTENANCE AND LUBRICATIONPeriodic Maintenance ScheduleWARNINGImproperly performing the procedures marked with a J could result in componentfailure