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A car d containing im port ant A TV s afet y inf orm ation s hould be att ached to t he owner ’s manual on the next page. If you cannot locate t his c ard, or if it has been rem oved, please call 1-800- 342-3764 f or ass ist ance. The engine exhaust from this product contains chemical s known to cause cancer , birth defects or other reproductive harm.
2 Copyri ght 2004 Pol ar is Sal es I nc. All inf orma ti on cont ai ned w ithi n thi s publ ic at ion i s bas e d on the la te st pr oduct i nfor mat ion at t he ti me of publi ca ti on. Due to cons tant imp ro vem ents in the desig n an d q uality o f pr oduct ion compone nts , some m inor discrep an cies may result betw een th e actual vehicle and th e info rm ation p resen ted in th is publi ca ti on.
3 WELC OME Thank you for purcha sing a Polaris vehic le, and welc ome to our world-w ide family of Polaris owner s. W e proudly produce a n exciting line of utility a nd rec rea tional produc ts. Polaris R ecreational and Utility V ehicles S Snowmobiles S All-te rra in vehicle s (A TVs) S W atercraft S V ict ory m ot orcy cles S RANGER utility vehicle s W e believe Polar is sets a standard of exc ellenc e for all utility and rec rea tional vehic les manufa ctured in the world toda y .
5 TABLE OF CONTENTS WELCO ME 3 ................................. VEHICLE IDENT IFI CA TION NUM BERS 7 ........ SAFET Y 8 ................................... FEA TURES AND CONTROLS 32 ............... OPER A TION 44 ........................
7 VEHICLE IDE NTIFICATION NUMBERS Recor d your A TV’ s identification numbe rs and key numbe r in the spaces prov ided . R emo ve t he sp are key an d s to re it in a s afe pl ace. Y our key can be duplicated only by mating a P olaris ke y blank with one of your existing ke ys, so if both keys are lost, the ignition switc h mus t be replaced .
8 SAFE TY Operator S afety W ARNING Failur e to f ollow the war nings cont ained in t his manual c an result in serious injury or deat h. A Polar is A T V is not a toy and can be hazardous to operat e. T his vehicle handles differently than ot her vehic les, such as motorcycles and cars.
9 SAFE TY Operator S afety The following signa l words and symbols appe ar throughout this manual a nd on your A TV . Y our safe ty is involved when the se words and symbols are use d. Be come fa miliar with their mea nings before rea ding the manual.
10 SAFE TY Operator S afety W ARNING Serious injury or deat h can res ult if you do not follow thes e instr uct ions and proc edures, which are out lined in f urt her det ail within your owner ’ s manual. S Read this ma nual and a ll labels car efully , and follow the ope rating proce dures desc ribed.
11 SAFE TY Operator S afety S Always have th e A TV in spect ed by an au th ori zed Po lari s deal er if it’ s been i nvolved i n an accident. S Neve r opera te on hills too stee p for the A TV or for your abilities. Pra ctice on sma ller hills befor e attempting la rge r hills.
12 SAFE TY Operator S afety S W et brake s may have re duced stopping a bility . T est your bra kes afte r lea ving water . If nec essary , apply them lightly seve ral times to a llow frict ion t o dry o ut t he pads . S Always chec k for obstacles or people behind the A TV before oper at- ing i n revers e.
13 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V wit hout proper inst ruc tion. WHA T CAN HAPPEN The r isk of an accident is great ly incr eased if the operat or does not know how to operat e the A TV pr operly in diff erent situat ions and on different types of t errain.
14 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Carry ing a passenger on an AT V. WHA T CAN HAPPEN Carry ing a passenger great ly reduces t he operat or ’ s ability t o balance and contr ol t he A TV , whic h could caus e an accident and injury t o the operat or and/or pass enger .
15 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t his A T V on public str eets , roads or highways. WHA T CAN HAPPEN The A T V c ould collide with anot her vehic le. HOW TO A VOID THE HAZARD Never oper ate t he A T V on any public st reet , r oad or highway , including dirt and gravel r oads.
16 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V af ter consuming alcohol or dr ugs. WHA T CAN HAPPEN Consumpt ion of alc ohol and/or drugs could ser iously aff ect operator judgment . Reac tion t ime m ay be slower and operat or balance and per cept ion could be affec ted.
17 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Att empt ing wheelies, jumps and other stunt s. WHA T CAN HAPPEN Att empt ing st unt s incr eases the c hance of an ac cident , including an over tur n. HOW TO A VOID THE HAZA RD Never att empt wheelies, jumps, or ot her st unt s.
18 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Removing hands from the handlebars or feet from the f ootr est s during operat ion. WHA T CAN HAPPEN Removing ev en one hand or f oot c an reduce abilit y t o cont rol t he vehicle or could cause loss of balance and ejec tion f rom the A T V .
19 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Failu re to use extra caution w hen operat ing on exces sively r ough, slippery or loose ter rain. WHA T CAN HAPPEN Operatin g on excessive ly rough, s lippery or loose terr ain could caus e loss of tr acti on or loss of cont rol, which could r esult in an accident or overt urn.
20 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Operat ing on exc essiv ely st eep hills. WHA T CAN HAPPEN The v ehicle may overtur n. HOW TO A VOID THE HAZARD Never oper ate on hills t oo st eep f or t he A T V or f or y our abilit ies.
21 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD T raveling downhill improper ly . WHA T CAN HAPPEN Impr operly descending a hill could caus e loss of contr ol or overt urn. HOW TO A VOID THE HAZA RD Always f ollow proper procedur es for t rav eling down hills as des cribed in the owner ’s manual.
22 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Impr operly c ross ing hills and turning on hills . WHA T CAN HAPPEN Im properly crossing or turning as hills could caus e loss of contr ol or over tur n. HOW TO A VOID THE HAZA RD N e v e ra t t e m p t t ot u r nt h e A TV around on any hill unt il you’ve m aster ed the t urning tec hnique (on level gr ound) as desc ribed in the owner ’s manual.
23 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Stalling, rolling back wards or improper ly dismount ing while climbing a hill. WHA T CAN HAPPEN The v ehicle could ov ertur n. HOW TO A VOID THE HAZA RD Maint ain steady speed when climbing a hill.
24 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Im properly operating over obstac les. WHA T CAN HAPPEN Oper ating over obstac les could c ause loss of cont rol or overt urn. HOW TO A VOID THE HAZARD Befor e operat ing in a new area, check f or obs tac les.
25 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V t hrough deep or f ast -f lowing wat er . WHA T CAN HAPPEN T ires m ay float , caus ing loss of t ract ion and loss of cont rol, which could lead t o an accident or over turn.
26 SAFE TY Operator S afety W ARNING POTENTI AL HAZA RD Oper ating t he A T V wit h improper modific ations . WHA T CAN HAPPEN Im proper ins tallat ion of ac cess ories or modific ation of the A TV may c ause changes in handling which could lead to an ac cident .
27 SAFE TY Operator S afety W ARNING Leaving the k eys in t he ignit ion can lead t o unauthor ized use of the vehic le result ing in ser ious injury or death. A lways r emove the ignit ion key when the vehicle is not in use. W ARNING Aft er any overt urn or ac cident , hav e a qualified s ervic e dealer inspect the ent ire vehic le for possible damage, including (but not limited to ) brakes, throttle and steerin g systems.
28 SAFE TY Safety D ecals and Locations W arni ng decals have been placed on the A TV for your protection. Read and fol lo w th e ins tru cti ons of the decal s and o th er warni ngs o n th e A TV carefu ll y . If any of th e decal s sh own in t hi s man ual differ from the decals o n your A TV , always read and follow the ins truct ions of the decal s on the A TV .
29 SAFE TY Safety D ecals and Locations Improper A TV use can result in SEVERE INJU R Y or DEA TH ALW A YS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARR Y P ASSENGE.
30 SAFE TY Safety D ecals and Locations Chain Freeplay Is Import ant. Adjust F ree play to 3/1 6 ″ -3 / 8 ″ DO NOT O vertensi on. See Owner’s Manual . T orque Nut on Ecc entric Bol ts: T o 30 Ft. Lbs. (For models without a hitch). T o 40 Ft.
31 SAFE TY Safe R iding Gear Always wea r clothing suited to the t ype of riding. A TV riding requir es specia l protective clothing for c omfort and to reduce the c hance of injury . 1. Helmet Y our helmet is the most important pie ce of protec tive gear f or safe r iding.
32 FEATURES AND CONTROLS Electr ical Switches W ARNING Act ivat ing the ov erride s witc h while the t hrot t le is open can c ause loss of contr ol, r esult ing in sever e injury or death. Do not activat e the over ride swit ch while t he t hrot tle is open.
33 FEATURES AND CONTROLS W ARNING Do not st art or operat e an A T V wit h st ick ing or impr operly operat ing throt t le cont rols, which could c ause an acc ident and lead to sev ere injur y or deat h. Always cont act your dealer f or serv ice repairs if thr ott le problems arise.
34 FEATURES AND CONTROLS W ARNING Oper ating t he A T V on st reet s or roads, especially in dar kness , could res ult in an ac cident and serious injury or death. Y our A T V is not equipped wit h highway-appr oved light s. I t’s designed f or and mus t be us ed for off -road us e only .
35 FEATURES AND CONTROLS Br akes Ch eck t he brak e flu id level in t he m ast er cyli nd er befo re each u se of t he A TV . The maste r cylinder ( 1) is located on the l eft handl ebar . 1. Position the A TV on level ground with the handle bars stra ight.
36 FEATURES AND CONTROLS Br ake Lever The fro nt and rear brak es are ap pl ied by squ eezin g th e brak e lever (1 ) to ward t he hand leb ar . The fro nt and rear b rakes are hydraulic ally ac tivated disc type brake s that are activ ated b y on ly o ne lev er .
37 FEATURES AND CONTROLS Park ing B rake W ARNING Oper ating t he A T V while t he parking br ake is engaged c ould result in an acci dent and serious injur y or death. Alway s check t o be sure t he park ing brake is disengaged before oper ating.
38 FEATURES AND CONTROLS Auxiliary Brake W ARNING Aggres sively applying the rear brake when back ing downhill may cause r ear t ipover , which could result in serious injury or deat h. Use caut ion when applying t he auxiliary brake. Do not aggress ively apply the auxiliary brake when going f orward.
39 FEATURES AND CONTROLS Choke The choke assists in starting a co ld engine. Refer to the engine star ting proce dure on page 47 for cor rect choke a nd throttle settings during starting. Fuel V alve The fu el v alve (1 ) i s l ocat ed on the l eft s id e of the vehic le, below the fender .
40 FEATURES AND CONTROLS Fuel Safety W ARNING Gasoline is highly flam mable and explos ive under c ert ain conditi ons. S Always exercise ex tr eme caut ion whenever handling gasoline. S Always refuel wit h the engine s topped, and outdoor s or in a well ventilat ed area.
41 FEATURES AND CONTROLS Oil Injection T ank CAUTION Mixing br ands or us ing a non-rec ommended oil m ay caus e serious engine damage. We recomm end the us e of P olaris Premium S ynthetic 2-cycle oil for yo ur 2-cycle Po laris A TV . Never subs tit ute or mix oil brands .
42 FEATURES AND CONTROLS Automatic T r ansm ission Gear Selector The transmission gea r selec tor (1) is located on the right side of the A TV . F: For war d N: Neutral R: Rev erse CAUTION Shift ing gears with t he engine speed above idle or while the vehicle is moving could caus e tr ansmi ssion dam age.
43 FEATURES AND CONTROLS Recoil Star ter If the batter y has bee n drained or damage d and ca nnot start the engine, use of the re coil starter ( 1) will allow vehic le opera tion until repa irs can be made . The recoil starte r is locate d on the right side of t he m achi ne.
44 OPERATION Br eak-In Per iod The brea k-in period for your ne w Polaris A TV is defined as the time it takes to use the first tank of f uel. No single action o n your part is as important as following the proc edures for a prope r brea k-in. Caref ul treat men t o f a new en gin e wil l result in more efficien t p erform ance and longer life f or the engine.
45 OPERATION Br eak-In Per iod The firs t t ank of fuel m us t be pre-m ix ed accordi ng t o th e foll owi ng instruc tions. Afte r the break -in period, the oil injection system will provide the nec essar y engine lubrication without pre -mixing. 1.
46 OPERATION Pr e -Ride Inspection W ARNING If a proper inspec tion is not done bef ore each us e, s evere injur y or deat h could res ult. Alway s inspec t t he vehic le befor e each use to ens ure it ’s in proper operat ing condit ion.
47 OPERATION Star ting the E ngine Sta rting a C old Engi ne W ARNING Engine exhaus t cont ains pois onous car bon monoxide and c an cause los s of consciousnes s res ulting in s evere injur y or deat h. Never r un an engine in an enclosed ar ea. CAUTION Oper ating t he vehicle im mediat ely af ter star ting c ould cause engine damage.
48 OPERATION Star ting the E ngine Sta rting a W ar m Engine W arm engines do not normally require the use of the c hoke. Excessive use of the choke ca n cause the spark plug to become we t fouled. 1. Position the vehicle on a leve l surfac e and place the tr ansmission in neutra l.
49 OPERATION Driving Safely Driving Pr oced ures 1. Sit upright with both fee t on the footrests a nd both hands on the handleba rs. 2. Start the engine and allow it to war m up, then shift the transmission into gea r . 3. Check your surroundings and de termine your path of tr avel.
50 OPERATION Driving Safely Making T urns Y our Polaris A TV is equipped w ith a solid rea r axle that drive s both rea r whe els equa lly at all time s. This mea ns that the whee l on the outside of the turn must travel a grea ter distance tha n the inside wheel whe n turning and the inside tire must slip trac tion slightly .
51 OPERATION Driving Safely Driving on Slippery S urfaces Whenev er ridi ng o n sl ipp ery su rfaces such as wet trai ls or loo se grav el, or duri ng freezi ng weat her , fo ll ow t hese precau ti on s: 1. Slow down when ente ring slippery a reas.
52 OPERATION Driving Safely Driving Uphill Whe neve r trave ling uphill, follow thes e precau ti on s: 1. Alwa ys trave l straight uphill. 2. A void steep hills (25 _ maximum) . 3. Keep both f eet on the footre sts. 4. T ransfer your weight for ward.
53 OPERATION Driving Safely Sidehilling W ARNING Impr operly crossing hills or tur ning on hills can r esult in loss of contr ol or v ehicle over tur n, r esult ing in sever e injury or death. Avoid cross ing the s ide of a hill when pos sible. Follow proper procedur es as out lined in the owner ’s manual.
54 OPERATION Driving Safely Driving Downhill Whe never de scending a hill, follow these pr ecauti on s: 1. P ro ceed di rectl y dow nh ill. 2. T ransfe r your weight to the rear of the ve hicle. 3. Slow down. 4. Apply the brakes slightly to aid in slowing, using the single bra ke leve r .
55 OPERATION Driving Safely T urni ng Ar ound on a Hill W ARNING Im proper hill c limbing proc edures c ould cause los s of control or overt urn and r esult in s erious injury or deat h. Avoid climbing st eep hills ( 25 _ maximum). Use ext reme c aution when oper ating on hills , and f ollow proper operat ing procedur es outlined in t he owner ’s manual.
56 OPERATION Driving Safely Dr iving Thr ough W ater Y our A TV can ope rate through wate r with a max imum recomme nded depth equal to the bottom of the footrests (1). Follow these procedur es when oper ating through water : 1. Deter mine water depths and cur rent befor e crossing.
57 OPERATION Driving Safely Dr iving Thr ough W ater CAUTION Major engine dam age can res ult if the vehic le is not thoroughly inspect ed aft er oper ation in wat er. Perf orm the ser vices outlined in the m aintenance c hart . If your vehic le becomes immers ed or is oper ated in wat er t hat exceeds the foot res t lev el, t ake it to y our dealer f or s ervic e befor e star ti ng the engine.
58 OPERATION Driving Safely Driving Over Obstacles Be alert ! L ook ah ead and l earn to read t he t errain y ou’re tr aveli ng o n. Be con st ant ly al ert for h azards su ch as l ogs , ro cks an d low h angi ng branch es. W ARNING Severe injur y or death can res ult if your v ehicle com es in cont act with a hidden obst acle.
59 OPERATION Driving Safely Driving in Rever se Fo ll ow t hes e precau ti on s when op erati ng in rev erse: 1. Always avoid ba cking downhill. 2. Back slowly . 3. Wh en in rev erse, apply the brake s lightly for stopping. 4. A void turning at sharp angles in r ever se.
60 OPERATION Hauling Cargo Y our A TV has bee n designed to ca rry or tow a certain a mount of load (if e quipped with ra cks). Always rea d and under stand the load dis t ribu ti on w arnin g lab els o n th e vehi cle, and nev er exceed th e weigh t cap acities outline d in the spec ifications se ction of the ow ner ’ s manual and on t he safet y decal s.
61 OPERATION Hauling Cargo W ARNING Hauling cargo im properly can alter v ehicle handling and may cause los s of c ontr ol or brak e inst ability and result in serious injury or deat h. Always f ollow these prec autions when hauling cargo: S REDUCE SPEED AN D ALLOW GREA T ER DIST ANCE FO R BRAKING WHEN H AULING CARGO.
62 OPERATION Driving Safely P a r k i n go na nI n c l i n e A void parking on an inc line if possible. If it’ s unavoidable , follow thes e precau ti on s: 1. T urn the engine off . 2. Place the tra nsmission in gear . 3. Set the parking brake.
63 EMISSION C ONT RO L SYST EMS Noise Em ission C ontrol System Do not modify the engine, intake o r exhaust components, as doing so may af fect complia nce with state a nd local noise level requir ements. Spar k Ar restor Y our Polaris vehicle has a spa rk arr estor that wa s tested and a pproved in accordance wi th the USDA F or est Servi ce St andard 5100-1C.
64 MAINTENANCE AND LUBRICATION Accessor ies Auxiliar y power outlets provide 12V powe r for opera ting access ori es such as ha nd held spot lights. See your Pola ris dealer . Per iodic Maintenance Char t Care ful periodic mainten ance will help keep your vehic le in t he safe st, most relia ble condition.
65 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Perfo rm all s ervices at wh ich ever main ten ance int erval i s reached firs t. Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Steering -- P re-R ide -- Mak e adjustments as need- e d S e e P r e R i d e C h e c k l i s t " Front s us pension -- Pre- Ride -- j ed.
66 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) Carbur etor float bowl 50 H 6M 500 (800) Drain bowl per iodically and prior to s tor age J E Throttle C able/ ETC Switch 50 H 6M 500 (800) Inspec t; adjus t; lubric ate; replac e if nec ess ar y J E Chok e c able 50 H 6M 500 (800) Inspec t; adjus t; lubric ate; replac e if nec ess ar y E Carbur etor air intake ducts / flange 50 H 6M 500 (800) Inspec t duc ts for proper sealing/air l eaks Driv e belt 50 H 6M 500 (800) Inspec t; adjus t; replac e as needed " E Engine oil c hange 100 H 6M 1000 (1600) Perfor m a break -in oil change at one month " E Oil filt er c hange 100 H 6M 1000 (1600) Replac e with oil c hange J E V alve c learanc e 100 H 12 M 1000 (1600) Inspect ; adjust J E Fu el syst em 100 H 12 M 1000 (1600) Check for leak s at tank c ap, lines, fuel v alv e, filter, pump, car buretor ; replac e lines ever y t wo y ears J E Fuel filter 100 H 12 M 1000 (1600) Replace y early " Engine mounts 100 H 12 M 1000 (1600) Inspec t Ex haust muffler/ pipe 100 H 12 M 1000 (1600) Ins pec t J E Spark plug 100 H 12 M 1000 ( 1600) Inspec t; r eplac e as needed J E Ignition Timing 100 H 12 M 1000 (1600) Inspec t " Wiring 100 H 12 M 1000 (1600) Inspec t f or wear, routing, sec urit y; apply dielect ric greas e to c onnect ors subjec ted to w ater, mud, etc.
67 MAINTENANCE AND LUBRICATION Per iodic Maintenance Char t Item Maintenance I nter val (whic hev er c omes fir s t) Remarks Hours Calendar Miles (Km) J Brak e fluid 200 H 24 M 2000 (3200) C hange ever y tw o year s Spark ar res tor 300 H 36 M 3000 (4800) C lean out E Idle speed -- Adjus t as needed J T oe adjus tment -- Inspec t per iodically ; adjus t when part s ar e replac ed Headlight aim -- Adjust as needed " Perf orm t hese procedur es more of ten f or vehicl es subject ed to sever e use.
68 MAINTENANCE AND LUBRICATION Per iodic Main tenance Record Use th e fol lo wing chart t o reco rd peri od ic m ain tenan ce. Maintenance In terval Perfo rmed Ser vic ing Date Ser vic ing Dealer or Pe rson Remarks 10 hrs. 20 hrs. 50 hrs. 100 hrs.
69 MAINTENANCE AND LUBRICATION Lubri cation Re comm endations Chec k and lubrica te all compone nts at the inter vals outlined in the Periodic Maintena nce Chart beginning on page 65. Lubri cation C hart K ey " More of ten under se vere use , such as wet or dusty conditions L Polaris Pre mium All Season G rea se or gre ase c onforming to NL G No.
70 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations Pol aris 2- Cycle Lubr icants Polaris Premium 2-c ycle lubric ants are the most advanc ed formula tion of oils, specifica lly designed for today’ s 2-cycle engines. These lubrica nts provide additives for 2- cycle engine s that are lacking in today’ s fuel.
71 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations Engi ne Oil Chec k The oi l tan k cap (1) is l ocat ed forward of the head light. Check the oil befor e each us e of t he v ehi cle. R efi ll the o il when refuel in g. 1. Position the A TV on a level surface.
72 MAINTENANCE AND LUBRICATION Lubricati on Recom m endations T ransmission Oil Check The tr ansmission oil dipstick (1) is locate d on the right side of the vehicle. Check and cha nge the transmission oil at t he interva ls outlined in the Periodic Mainte nanc e Chart beginning on page 65.
73 MAINTENANCE AND LUBRICATION Adjus tments Oil Pump Bleeding CAUTION If the oil supply line has been disconnec ted f rom the pump, or if the oil r eservoir and supply line have been c omplet ely run out of oil, t he oil pump mus t be bled. I f the pump is not bled, air in the lines may prevent oil deliv ery t o t he engine, r esult ing in sever e engine damage.
74 MAINTENANCE AND LUBRICATION Adjus tments Oil Pump If it become s nece ssary to incre ase oil flow into the fuel system, the oil pum p can be adj us ted . 1. Befor e adjusting the oil pump, che ck the engine idle RPM and carbur etor settings in the spec ifica tions section beg inning on page 103.
75 MAINTENANCE AND LUBRICATION Adjus tments Brakes The front and re ar brake s are hydraulic disc br akes, activate d by moving the single brake leve r toward the handleba r . These brakes ar e self- adjusting. The fo ll owi ng ch ecks are recomm ended to keep the b rake sy st em i n good opera ting condition.
76 MAINTENANCE AND LUBRICATION Adjus tments W ARNING Sever e injury or death can res ult f rom improper t oe alignment and adjustm ent. Do not att empt to adjus t t ie rod alignment . All t ie rod adjustm ents should be perf ormed by an authoriz ed Polaris dealer .
77 MAINTENANCE AND LUBRICATION Adjus tments Steering Assem bly The stee ring asse mbly of the A TV should be chec ked per iodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris deale r for servic e before ope rating the vehicle.
78 MAINTENANCE AND LUBRICATION Adjus tments W ARNING Im proper adjust ment of t he handlebars or incorrect t orquing of the adjust er bloc k t ightening bolt s c an cause lim ited s teer ing or loosening of t he handlebars , r esult ing in loss of cont rol and possible s erious per sonal injury or death.
79 MAINTENANCE AND LUBRICATION Adjus tments Car bure tor IMPOR T ANT : Y our Polaris A TV is calibr ated a t the fac tory for optimal per formanc e at altitude s ranging fr om zero to 6,000 fe et (1800 m) and tempera tures of +40 degre es F . (4 degre es C.
80 MAINTENANCE AND LUBRICATION Adjus tments W ARNING Operat ing your A TV with worn t ires , im properly inflated t ires , non-st andard tir es or impr operly inst alled tires will affec t vehic le handling and could caus e an accident result ing in serious injury or death.
81 MAINTENANCE AND LUBRICATION Adjus tments Wheel Installation 1. Place the t ransmission in ge ar an d lock the parking b rake. W ARNING Im properly ins talled wheels can adver sely affect tir e wear and vehicle handling, which can res ult in s erious injur y or deat h.
82 MAINTENANCE AND LUBRICATION Adjus tments Front W heel Hub T ightening Front wheel be aring tightness a nd spindle nut rete ntion are c ritica l component ope rations. All servic e must be p erfor med by your auth ori zed P ol aris d ealer . Tir e T read Depth Always rep lace ti res when t read depth is worn to 1/8 ″ ( .
83 MAINTENANCE AND LUBRICATION Adjus tments Drive Chain Polaris A TV drive chains are e quipped with o-ring-se aled, perma nently greased pin s an d rol l ers. Ho wever, the o ut er su rfaces o f th e rol ler m us t be lubrica ted. 1. Always inspect the drive cha in prior to operating the vehicle.
84 MAINTENANCE AND LUBRICATION Adjus tments Rear Dr ive Cha in Slack CAUTION Adjust ing or operat ing t he A T V wit h improper rear driv e chain slack can result in severe dam age to t he t ransm ission and dr ive component s. Always m ake sur e the s lack is within t he stat ed specif icat ions.
85 MAINTENANCE AND LUBRICATION Adjus tments Rear Dr ive Cha in Slack 1. R ol l t he A TV fo rward or b ackward to adjust the c hain slac k to the proper te nsion. See the illustration for prope r splice link clip opening position (1). 2. Tight en t he eccen tri c lo cki ng bol ts to 30 ft.
86 MAINTENANCE AND LUBRICATION Filter System s Air Filter Removal and Service 1. Remove the A TV seat. 2. Relea se the clips secur ing the cover asse mbly to the air box. 3. Loosen the cla mp secur ing the filter , and remove the filte r . 4.
87 MAINTENANCE AND LUBRICATION Lights Whe n servicing a halogen la mp, don’t touch the la mp with bare finger s. Oil from your skin leav es a re sidue, cau sing a hot spot that will shorten the life of the la mp. W ARNING Poor light ing while driv ing can result in sever e injury or death.
88 MAINTENANCE AND LUBRICATION Lights Headlight Adjustment 1. Position the vehicle on a level surface wi t h th e hea dlight approximate ly 25 ft. (7. 6 m) from a fla t wall. 2. Measur e the distance from the floor to the cent er of t he head li gh t and mak e a mark on t he wall at th e sam e hei gh t.
89 MAINTENANCE AND LUBRICATION Lights T aillight /Brakelight Lamp Replacement If the taillight/bra kelight does not work the lamp may ne ed to be replaced . 1. Remove the taillight lens cove r mounting scre ws. Remove the lens cove r and gaske t and set aside for r easse mbly .
90 MAINTENANCE AND LUBRICATION Spar k Pl ugs Always use the spa rk plugs rec ommended for your A TV . Refer to the specif ications sec tion beginning on pa ge 103 f or the r ecomme nded spa rk plug type and ga p. CAUTION Using non-r ecomm ended spark plugs can result in serious engine damage.
91 MAINTENANCE AND LUBRICATION V ehi cle I mmersi on CAUTION If your vehic le becomes immers ed, m ajor engine damage c an result if t he machine is not t horoughly ins pect ed. T ak e the vehicle t o your dealer before s tar ting t he engine.
92 MAINTENANCE AND LUBRICATION Spar k Ar restor W ARNING Failur e to heed t he following war nings while ser vicing t he spar k arres tor could r esult in s erious injur y or deat h. Do no t pe rform service on the spa rk arrestor while the system is hot.
93 MAINTENANCE AND LUBRICATION Recoil Hous ing T o prevent possible engine dama ge, always dra in the recoil housing ( 1) a f t e ro p e r a t i n gt h eA T Vi nv e r yw e t conditions. This should also be done befor e storing the A TV . W ater will ente r the rec oil housing if the starte r handle is disengaged from the rope guide when under water .
94 MAINTENANCE AND LUBRICATION PV T System The basic oper ation of the Polaris PVT syste m is depe ndent on engine speed and veh icl e to rqu e requi remen ts . As engi ne s peed increas es, the forc e exerte d on the movable dr ive sheave by the flyweights also incre ases.
95 MAINTENANCE AND LUBRICATION PV T System W ARNING Failure t o com ply wit h the ins tr uct ions in t his warning can r esult in sever e injury or death. Do not modify any component of th e PVT syst em. Doing so may reduce it s s tr ength so t hat a failure m ay occ ur at a high speed.
96 MAINTENANCE AND LUBRICATION Batter y W ARNING Im properly connecting or disconnect ing bat ter y cables can result in an explosion and c ause ser ious injury or death. W hen remov ing the bat ter y , always disc onnect the negat ive (blac k) cable fir st .
97 MAINTENANCE AND LUBRICATION Batter y Batter y Stor age Whe never the ve hicle is not used for a period of three months or more, remov e th e bat tery from t he veh icl e, ensu re that it ’ s fu ll y ch arged, an d st ore it o ut o f the su n in a coo l, dry pl ace.
98 MAINTENANCE AND LUBRICATION Batter y Batt ery Charg ing NOT E: Alway s ver ify batt ery c ondition bef ore and 1- 2 hours af t er t he end of c harging. Stat e of Charge Vo l t a g e Acti on Charge T ime* (Us ing cons tant cur rent char ger @ s tandard amps spec ified on top of battery) 100% 12.
99 MAINTENANCE AND LUBRICATION Cleaning and S tor age See page 106 for the par t numbers of Polaris products. Cleaning the A T V Keep ing your A TV cle an will not only improve its appe ara nce but it ca n also extend the life of var ious components.
100 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s See page 106 for the par t numbers of Polaris products. CAUTION Star ting t he engine during t he st orage per iod will dist urb t he prot ecti ve film c reat ed by f ogging and damage could oc cur .
101 MAINTENANCE AND LUBRICATION Cleaning and S tor age Sto rag e Tip s See page 106 for the par t numbers of Polaris products. Engine Use Polaris Fogging Oil and fo llow the directions on the can. If you choose not to use P olaris Fogging Oil, perform the following proce dure.
102 MAINTENANCE AND LUBRICATION Cleaning and S tor age Chr ome W heel Car e (if equipped) Pro per mai nten ance wil l prot ect chro me wheel s from corros io n, preserv e wheel life an d ens ure a “l ik e new” app earance for many y ears. 1. W ash chrome r ims frequently .
103 SPECIFICA TIO NS 2005 T r ail Blazer Capac ities Body Styl e Gen III Gro ss V ehicle W eigh t 765 lbs . ( 347 kg) Fu el C apacity 3.5 U.S. ga l. (13. 2 l) Engine Oi l 2 qts . ( 1.89 l ) Transm issio n Oil 11.3 o z. (.33 l) Fro n t R ack (A ccesso ry ) (Max imu m C apacity ) 30 lbs .
104 SPECIFICA TIO NS 2005 T r ail Blazer Drive S ystem Dri ve Sys te m T ype PVT Shif t T ype Si de Leve r (F- N-R) Gear R edu ctio n - L o w No t Ap p licab le Gea r Reduc tion - Reve rs e 3.05/ 1 Gear R edu ctio n - F o rward 2. 68/1 Fro n t Driv e (ratio ) No t Ap p licab le Fin al D rive (ratio ) 11/ 36 76P Cen ter D rive (ratio ) No t Ap p licab le Driv e Ch ain 520 O-Ri ng Front T ir e 2 3x7 - 1 0( 4p s i ) Rear Tire 22 x 11- 10 (3 ps i) Suspe nsi on and Brake s Front Sus pens ion Mc Pher son Str ut w/8.
105 SPECIFICA TIO NS 2005 T r ail Blazer Jetting Chart Altitude A mbient T emperatur e Below 0 ° F (Below - - 18 ° C) 0 ° to 40 ° F (- -1 8 ° Ct o + 5 ° C) + 40 ° to + 80 ° F ( + 5 ° Ct o + 26 ° C) + 80 ° F & Abov e ( + 26 ° C& Above) Meters ( Feet ) 0-900 (0-3000) 150 140 130 120 ( F e e t ) 900-1800 (3000-6000) 140 130 120 11 0 1800-2700 (6000-9000) 125 120 11 0 100 2700-3700 (9000-12000) 11 5 11 0 100 95 Turn air sc rew out 1/ 2 turn C CW f rom s eat.
106 POLARIS PRODUCTS Part No. Descri pti on Engine Lubr icant 2870791 Fogging Oi l ( 12 oz. Aer osol) 2871098 Premi um Blue 2-Cycl e Mineral Oi l (qt .) 2871097 Premi um Blue 2-Cycl e Mineral Oi l (gal .) 2871721 Premi um Gol d Syntheti c 2-Cycl e Oil ( qt.
107 TROUBLE SH OOTING Drive Belt and Cover Pr oblems Po ssib le Cau se Soluti on Dri ving t he A TV onto a pick u p o r tall trailer in high r ange . A void st opping on t he r am p or c re epi ng sl owly up t he ramp . Th ese practices may slip the clutch and b elt.
108 TROUBLE SH OOTING Contact your Polaris dea ler for servic e if you’re una ble to identify solutions using the following c harts. Engine Doesn’t T urn Over Possi bl e Cause Soluti on Lo w b attery v o ltage Re cha r ge ba tte ry t o 12.8 VDC Loose ba tt er y connec tions Ch eck all con n ectio ns and tig h ten Loose s ole noid conne c tions Ch eck all con n ectio ns and tig h ten Engine T urns Over , Fails to Star t Possi bl e Cause Soluti on Out of fuel Turn fu el valv e to reserve, refuel Clogge d fuel va lve or f ilter In sp ect and clean or rep lace W ater is p resen t in fu el Drain the fuel system an d refu el Fuel va lve i s tur ned of f T urn the f uel va lve on Old or non- re comme nded fue l Repl ac e wit h new fuel Foule d or de fe cti ve s par k plug( s) Insp ect p lu g (s), rep lace if n ecessary No s par k to s par k plug Insp ect plu g (s), verify sto p switch is on Cran k case filled w ith w ater o r fuel I mme dia te ly se e your Pola ri s dea le r Ove rus e of choke In sp ect, clean and /or rep lace spark plu g s Clogge d fuel f ilter Rep lace th e filter Lo w b attery v o ltage Re cha r ge ba tte ry t o 12.
109 TROUBLE SH OOTING Engine Backfires Possi bl e Cause Soluti on W ea k spa rk f rom s par k plugs Insp ect, clean and /o r replace spark p lu g s Inco rrect spark p lu g g ap o r heat rang e Set ga p to s pec s or r epl ac e pl ugs Old or non- re comme nded fue l Repl ac e wit h new fuel Inco rrectly in stalled sp ark plu g w ires Se e your Pola ri s dea le r Inco rrect ig n ition timin g See your Pol ar is de al er Mech an ical failure See your Pol ar is de al er Engi ne Runs Ir regul arly , Sta lls or Mi sfire s Possi bl e Weak Spar k Cause Sol utio n Foule d or de fe cti ve s par k plugs Insp ect, clean and /o r replace spark p lu g s W orn or de fec ti ve s pa rk plug w ir es See your Pol ar is de al er Inco rrect spark p lu g g ap o r heat rang e Set ga p to s pec s or r epl ac e pl ugs Lo o se ign itio n c onnec ti ons Ch eck all con n ectio ns and tig h ten W ater p resent in fu el Repl ac e wit h new fuel Lo w b attery v o ltage Re cha r ge ba tte ry t o 12.
11 0 TROUBLE SH OOTING Engi ne Stops or Loses Powe r Possi bl e Cause Soluti on Out of fuel Turn fu el valv e to reserve, refuel Kinke d or plugge d fue l vent li ne Insp ect and rep lace W ater p resent in fu el Repl ac e wit h new fuel Ove rus e of choke In sp ect, clean and /or rep lace spark plu g s Foule d or de fe cti ve s par k plugs Insp ect, clean and /o r replace spark p lu g s W orn or de fec ti ve s pa rk plug w ir es See your Pol ar is de al er Inco rrect spark p lu g g ap o r heat rang e Set ga p to s pec s or r epl ac e pl ugs Lo o se ign itio n c onnec ti ons Ch eck all con n ectio ns and tig h ten Lo w b attery v o ltage Re cha r ge ba tte ry t o 12.
111 WARRANTY LIM ITED W ARRANT Y Pola ri s Sal es I nc. , 2100 Highwa y 55, Medi na, MN 55340, gi ves a SIX MONTH L IMI TED W ARRANTY on al l compone nts o f the Pol ar is A ll T err ai n V ehi cl e (A TV) agai nst de fe ct s in m at er ia l or workma ns hip.
11 2 WARRANTY W ARRANT Y COVERAGE AND EXCL USIONS: LIMIT A TI ONS O F W ARRANTIE S AND REMEDI ES ALL IMPLI ED W ARRANTIES (I NCLUDING BUT NOT LIMI TED TO THE IMPLI ED W ARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LI MITED IN DURA TION TO THE ABOVE SIX MONTH W ARRAN- TY PERIOD.
11 3 WARRANTY Exported V eh icles EXCEPT WHERE SPECIFI CALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THI S VEHICLE IF I T IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. Th is po licy d oes no t app ly to v eh icles that hav e received auth o rizatio n fo r e xpor t fr om Pola ri s I ndust ri es .
11 4 INDEX A Accesso ries 6 4 ................... Adjus tment s 73-85 ................ Ag e R estriction s 8 ................ Air F ilter 86 ..................... Au x iliary B rak e 38 , 75 ............ B Bat te ry 96- 98 ............
11 5 INDEX O Oil 70 .......................... Oil In jectio n T ank 4 1 .............. Oil P ump Adjus tme nt 74 ........... Oil P u mp Bleed in g 7 3 ............. OPERA TION 44- 62 ............... Ope ra tor Sa fe ty 8- 27 .....
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