WELCOME
Thank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of utility and recreational products: S Snowmobiles S All-terrain vehicles (ATVs) and Quadricycles S RANGER utility vehicles S Victory motorcycles Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician. Please see your dealer for all of your service needs during (and after) the warranty period. For more information about Polaris, visit us online at www.polarisindustries.com.

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Any reprinting or reuse of the depictions and/or procedures contained within. whether whole or in part. is expressly prohibited. Depictions and/or procedures in this publication are intended for reference use only. some minor discrepancies may result between the actual vehicle and the information presented in this publication. Manufacturer accepts no liability for omissions or inaccuracies.Copyright 2005 Polaris Sales Inc. Printed in U. Due to constant improvements in the design and quality of production components. 2006 Sportsman 500/500 EFI International Owner’s Manual P/N 9920545 2 . All information contained within this publication is based on the latest product information at the time of publication.A.S.

. . . . . . . . . . . . . . 55 EMISSION CONTROL SYSTEMS . . . . . . . . . . . . . . 119 MAINTENANCE LOG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 FEATURES AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 WARRANTY . 111 SPECIFICATIONS . . . . . . . . . . . . . . . . . . 63 POLARIS PRODUCTS . . . . . . . . . . . . . . . . . . . . . 38 OPERATION . . . . . . . . . . . . 112 TROUBLESHOOTING . . . . . . . . . 121 INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .TABLE OF CONTENTS VEHICLE IDENTIFICATION NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 3 . . . . . . 62 MAINTENANCE AND LUBRICATION . . . . . . .

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Your key can be duplicated only by mating a Polaris key blank with one of your existing keys. the ignition switch must be replaced. 2 1 31XX 3 Vehicle Model Number: Frame VIN (1)(right front): Engine Serial Number (2): (right front of engine) Key Number (3): 5 . so if both keys are lost.VEHICLE IDENTIFICATION NUMBERS Record your vehicle’s identification numbers and key number. Remove the spare key and store it in a safe place.

CAUTION The safety alert caution indicates a potential hazard that may result in minor personal injury or damage to the vehicle. Become familiar with their meanings before reading the manual. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. NOTE: A note will alert you to important information or instructions. on your vehicle or in this manual. The safety alert symbol. CAUTION A caution indicates a situation that may result in damage to the vehicle. alerts you to the potential for personal injury. 6 .

even during routine maneuvers. Safety Training When you purchased your new Quadricycle. please request free safety training from any authorized Polaris dealer. Operation is prohibited for anyone under 16 years of age. if you fail to take proper precautions. Read and understand your owner’s manual and all warnings before operating a Polaris Quadricycle.Operator Safety SAFETY WARNING Failure to follow the warnings in this manual can result in serious injury or death. You were also provided with printed materials that explain safe operating procedures. Age Restriction This vehicle is an ADULT VEHICLE ONLY. If you purchased a used Polaris Quadricycle from a party other than a Polaris dealer. your dealer offered a hands-on safety training course. A collision or rollover can occur quickly. 7 . Review this information on a regular basis. A Polaris Quadricycle is not a toy and can be hazardous to operate.

Know their function and effect on the vehicle. It includes important information about Quadricycle safety. including (but not limited to) mowers. that increase speed or power. Use only Polaris-approved accessories. NOTE: The addition of certain accessories. Ride responsibly. the safety of others and the protection of the environment. sprayers and large racks may change vehicle handling. Restrictions This vehicle is approved for OFF-ROAD TOWING ONLY.SAFETY Operator Safety Know Your Vehicle and Riding Area You are responsible for your personal safety. tires. or if any modifications have been made. Equipment Modifications The warranty on your Polaris Quadricycle may be terminated if any equipment has been added. Read and understand your owner’s manual. Operating a Quadricycle/trailer combination on public roads is prohibited. blades. 8 . Know all laws and regulations concerning the operation of this vehicle in your area.

and have completed a certified safety training course. cautions and operating procedures in this manual and on the safety labels before operating the Quadricycle. Take a training course. Never operate a Quadricycle without proper instruction. < Never carry a passenger. 9 . Never permit others to operate the Quadricycle unless they have read and understand this manual and all product labels. Read and understand all warnings. Contact an authorized Polaris Quadricycle dealer or call Polaris at 1-800-342-3764. Never allow anyone under 16 years of age to operate this vehicle.Operator Safety SAFETY WARNING Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. Beginners should receive training from a certified instructor. The purpose of the long seat is to allow the operator to shift position.

gloves. Wear eye protection (goggles or face shield). Travel and turn at speeds appropriate for the terrain. 20 10 0 30 40 50 10 . boots.SAFETY Operator Safety Always wear an approved helmet that fits properly. long sleeves and long pants. operating conditions and your experience. Never consume alcohol or drugs before or while operating a Quadricycle. Never operate at excessive speeds. visibility.

Follow the inspection and maintenance procedures outlined in this manual. Keep your feet on the footrests. See page 56.Operator Safety Never attempt wheelies. Use extra caution. SAFETY Always inspect your Quadricycle before each use to verify that it’s in safe operating condition. Keep both hands on the handlebars. 11 . Always travel slowly when operating on unfamiliar terrain. jumps or other stunts.

always have an authorized Polaris dealer inspect the entire vehicle for possible damage. throttle and steering systems. Never turn sharply at excessive speeds. Always follow the procedures outlined in this manual for turning. If a Quadricycle has been involved in an accident. 12 . See page 24. which can lead to vehicle overturn.SAFETY Operator Safety Use caution when operating on rough. including (but not limited to) brake. slippery or loose terrain.

SAFETY >25_ Always follow the procedures outlined in this manual for crossing the side of a hill. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25_. See page 28. Never attempt to turn the Quadricycle around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. See page 27. 13 . Always follow the procedures outlined in this manual for climbing hills.Operator Safety Never operate on hills too steep for the Quadricycle or for your abilities. See page 32. Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

See page 26. 14 . Use extra caution. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces.SAFETY Operator Safety Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Always follow the procedures outlined in this manual for operating over obstacles. Always avoid skidding or sliding. Never back down a hill. See page 29. See page 25.

15 . Never drive through deep or fast-flowing water.Operator Safety Always follow the procedures outlined in this manual for driving through water. SAFETY Always follow the procedures outlined in this manual for driving in reverse. See page 33. Always use the size and type of tires specified for your Quadricycle. Maintain the proper tire pressure. See page 34.

Never exceed the stated load capacity for your Quadricycle. Never operate the Quadricycle on a frozen body of water. Avoid sudden turns or swift movement of the handlebars.SAFETY Operator Safety Never modify a Quadricycle through improper installation or use of accessories. 1/3 2/3 Always use low range when operating on pavement. Operating on paved surfaces may seriously affect the handling and control of the Quadricycle and could result in loss of control. and/or injury. 16 . Reduce speed and follow the instructions in this manual for carrying cargo or towing. accident. Allow a greater distance for braking. 2/3 Cargo must be 1/3 properly distributed and securely attached.

Operator Safety Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting. call Polaris at 1-800-342-3764. 17 . SAFETY Always keep combustible materials away from the exhaust system. Exposure of combustibles to hot components could result in a fire. FOR MORE INFORMATION ABOUT Quadricycle SAFETY.

The part number is printed on the decal. A 18 . contact your Polaris dealer to purchase a replacement. when going up or down. Read and follow the instructions on each decal carefully. To prevent flipover on hilly terrain. Replacement safety decals are provided by Polaris at no charge. use throttle and brakes gradually. If a decal becomes illegible or comes off.SAFETY Safety Decals and Locations Warning decals have been placed on the vehicle for your protection. B C D F E G A G Decal Text Never operate this vehicle on hills steeper than 25 degrees.

Safety Decals and Locations SAFETY C E B 19 .

(41 kg) Rear 180 lbs.5) REAR 5 (34. Vehicle damage or tipover may result causing severe injury or death. Max Rack Loads: Front 90 lbs. (546 kg) Read Owner’s Manual for more detailed loading information. Tow only from tow hooks or hitch.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE.SAFETY Safety Decals and Locations NO STEP D TIRE PRESSURE IN PSI (KPa): FRONT 5 (34. DRIVER AND CARGO IS 1200 LBS. (82 kg) 7172572 G 20 . 7173901 F WARNING DO NOT TOW FROM RACK OR BUMPER.

TRAILER MAX WEIGHT: 1225 LBS. especially in AWD. (386 KG) UP TO 15 DEGREE GRADE HITCH MAX. Loss of control or forward flipover may result. See Owner’s Manual. VERTICAL WEIGHT: 120 LBS. SAFETY ALL WHEEL DRIVE SWITCH Do not push switch to engage AWD if the rear wheels are spinning. (557 KG) ON LEVEL GROUND 850 LBS.Safety Decals and Locations Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. This may cause severe drive shaft and clutch damage. See your Owner’s Manual. (55 KG) 7170911 21 .

Do not wear loose clothing that can get entangled in the vehicle. 1 3. Eye Protection Wear shatterproof goggles or a shatterproof helmet face shield. tree branches or shrubs. Gloves Wear off-road style gloves with knuckle pads.SAFETY Safe Riding Gear Always wear protective clothing to reduce the chance of injury. A helmet can prevent a severe head injury. 5. Helmet Always wear a helmet that meets or exceeds established safety standards. 4 22 . like moto-cross boots. Clothing Wear long sleeves and long pants to protect arms and legs. 2 5 3 4. Use a lens anti-fogging product to keep them clean. 1. 2. Boots Wear strong over-the-calf boots with heels. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

Driving Safely Driving Procedures SAFETY 1. Drive slowly. Check your surroundings and determine your path of travel. then shift the transmission into gear. 4. 6. 2. Keep your feet on the footrests. 7. 23 . Slowly squeeze the throttle lever toward the handlebar to begin driving. 3. Start the engine and allow it to warm up. Apply the foot brake. Keep both hands on the handlebars. Release the foot brake. 5. Squeeze the throttle lever further to increase speed. Practice maneuvering and using the throttle and brakes on level surfaces. Sit upright.

24 . 20 10 0 30 40 50 Always follow the procedures outlined in this manual for turning. visibility. 2. Practice turning at slow speeds before attempting to turn at faster speeds. Use the same leaning technique for turning in reverse. Travel and turn at speeds appropriate for the terrain. leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.SAFETY Driving Safely Making Turns 1. operating conditions and your experience. Never turn sharply at excessive speeds. To make a turn. Never operate at excessive speeds. steer in the direction of the turn. which can lead to vehicle overturn.

follow these precautions: 1. gravel. Be alert. Engage AWD when the wheels have traction. Use extra caution. NOTE: To correct a rear wheel skid. turn the handlebars in the same direction as the skid and shift body weight forward. SAFETY 4. 25 . sharp turns. 2. Engage AWD before entering slippery areas. Always follow the procedures outlined in this manual for operating on slippery or loose surfaces.Driving Safely Driving on Slippery Surfaces Whenever driving on slippery or loose surfaces such as wet trails. snow or ice. Use extra caution. 3. CAUTION Severe damage to the drive train may occur if AWD is engaged while the wheels are spinning. Watch the trail. Avoid quick. Slow down before driving onto slippery surfaces. Always avoid skidding or sliding.

3. 2. Always check for obstacles before operating in a new area. Be alert. Watch the terrain. Use extra caution. Always follow the procedures outlined in this manual for operating over obstacles. Avoid hazards such as logs. 26 . rocks and low branches. Never operate over large obstacles. 4.SAFETY Driving Safely Driving Over Obstacles 1. Serious injury or death can result if your vehicle comes in contact with a hidden obstacle.

NOTE: If the vehicle begins to tip. Steer slightly into the hill. Shift your weight uphill. 3. Avoid hills with excessively slippery or loose surfaces. 6. follow these precautions: 1. 27 . 5. Never attempt to turn the Quadricycle around on any hill until you’ve mastered (on level ground) the turning technique outlined in this manual. If sidehilling is necessary.Driving Safely Sidehilling SAFETY Avoid crossing the side of a hill (sidehilling) if possible. 2. Keep your feet on the footrests. 4. quickly turn the front wheels downhill (if possible) or dismount on the uphill side immediately! Always follow the procedures outlined in this manual for crossing the side of a hill. Avoid crossing the sides of steep hills. Slow down.

Never open the throttle suddenly or make sudden gear changes. Shift your weight uphill.SAFETY Driving Safely Driving Uphill < 25_ Whenever traveling uphill. 9. This may include dismounting quickly. Be alert. Drive at a steady rate of speed to avoid stalling. Drive straight uphill. Never go over the top of a hill at high speed. Avoid steep hills (25_ maximum). 7. 5. Keep your feet on the footrests. Check the terrain carefully. Avoid hills with excessively slippery or loose surfaces. Be prepared to take emergency action. 6. 8. 3. 4. follow these precautions: 1. 10. 28 . 2.

If the vehicle begins rolling downhill. or to either side if the vehicle is pointed straight uphill. Never back down a hill. >25_ Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never apply the hand brake while rolling backwards. following the procedure described on page 30. Always follow the procedures outlined in this manual for climbing hills. Dismount on the uphill side. Apply the foot brake gradually. Avoid climbing hills steeper than 25_. never apply engine power. Turn the vehicle around and remount. apply the hand brake as well. Lock the hydraulic parking brake. When fully stopped. 29 .Driving Safely Driving Uphill SAFETY If all forward speed is lost: Keep your weight uphill.

never back down the hill! Use the K-turn to turn around. 7. 4. 30 . Squeeze the brake lever to release the parking brake. Slowly release the brake lever and allow the vehicle to roll around to your right until it’s pointing across the hill or slightly downward. Turn the engine off. 2.4 m 1. or on the left if the vehicle is pointing straight uphill. Leave the transmission in forward gear. 2. Dismount on the uphill side of the vehicle. 6. Stop the vehicle. 5.SAFETY Driving Safely Turning Around on a Hill If the vehicle stalls while climbing a hill. Lock the hydraulic parking brake. Stay uphill of the vehicle and turn the handlebars full left. 3. Keep your weight uphill.

Control speed with the foot brake until the vehicle is on level ground. Lock the hydraulic parking brake. 12. Keep your weight uphill. 11. Squeeze and release the brake lever to release the parking brake.Driving Safely Turning Around on a Hill SAFETY 8. start the engine. Always follow the procedures outlined in this manual for climbing hills. Remount from the uphill side. 10. See page 28. With the transmission still in forward. Apply the foot brake. 9. Release the foot brake and drive slowly downhill. 31 . >25_ Always follow the procedures outlined in this manual for crossing the side of a hill. See page 27.

Never operate at excessive speeds.SAFETY Driving Safely Driving Downhill Whenever descending a hill. 20 10 0 30 40 50 32 . Avoid going down a hill at an angle. 4. Shift your weight rearward. Always follow the procedures outlined in this manual for driving downhill and for braking on hills. 9. operating conditions and your experience. visibility. Travel and turn at speeds appropriate for the terrain. Apply the foot brake slightly to aid in slowing. 2. 7. which can cause the vehicle to pitch sharply to one side. Know how to use the hand brake. Drive straight downhill. Avoid hills with excessively slippery or loose surfaces. 6. 3. follow these precautions: 1. Never go down a hill at high speed. 5. 8. Slow down. Check the terrain carefully.

Always check for obstacles or people behind the vehicle before backing. CAUTION Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust. 6. 5. 3. Avoid backing downhill. Avoid turning at sharp angles. Never apply the throttle suddenly.Driving Safely Driving in Reverse SAFETY Follow these precautions when operating in reverse: 1. Always follow the procedures outlined in this manual for driving in reverse. 7. Do not use the override switch unless additional power is required for vehicle movement. 2. resulting in engine popping and/or engine damage. Do not operate at full throttle. 33 . Drive slowly. Apply the foot brake lightly for stopping. Use with caution. 4. NOTE: Reverse speed is greatly increased when the override switch is used. Apply just enough throttle to maintain the desired speed.

Avoid rocks and obstacles. Never drive through deep or fast-flowing water. 34 . Always test your brakes after leaving water.SAFETY Driving Safely Driving Through Water Follow these procedures when operating through water: 1. travel slowly. Avoid operating in water deeper than the bottom of the footrests (1). 3. If necessary. Always follow the procedures outlined in this manual for driving through water. apply them lightly several times to allow friction to dry out the pads. If it’s unavoidable. 4. Do not make sudden turns. Drive slowly. 6. Maintain a slow and steady forward motion. stops or 1 throttle changes. 5. 2. Check water depth and current before crossing. Wet brakes may have reduced stopping ability. Choose a crossing where both banks have gradual inclines. balance your weight carefully and avoid sudden movements.

If it’s unavoidable. NOTE: If water has been ingested into the transmission (PVT). If your vehicle becomes fully immersed. Take the vehicle to your dealer before starting the engine. Place the transmission in PARK.Driving Safely Driving Through Water SAFETY CAUTION If the vehicle stops while fully submerged. follow the steps described on page 98. 3. and it’s impossible to take it to a dealer before starting it. Turn the engine off. Parking on an Incline Avoid parking on an incline. 4. 35 . follow these precautions: 1. 2. Always block the rear wheels on the downhill side. major engine damage can result if the machine is not thoroughly inspected. Have the vehicle serviced by your dealer promptly. Turn the fuel valve off (if equipped). follow the procedure on page 61.

Unsecured loads can create unstable operating conditions. S DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack. while cornering. S CARRYING A LOAD on only one rack may cause the vehicle to overturn. 36 . securely fasten the load and operate with extra caution. with 1/3 in the front and 2/3 in the back. See specifications beginning on page 112. Operating a Quadricycle/trailer combination on public roads is prohibited. which could result in loss of control of the vehicle. or while ascending or descending hills. Reduce load weight when cargo is high. S CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Secure off-centered loads that cannot be centered and operate with extra caution. S Read and understand the load distribution warnings listed on the vehicle warning labels. causing the vehicle to overturn. Avoid situations that require backing downhill. cargo and towed load to maintain stable driving conditions. Stability and maneuverability may be adversely affected. S REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. S Never exceed the stated load capacity for this vehicle. Split the load between the front rack and rear rack. Do not exceed load capacities. reduce speed. Use extreme caution when applying brakes. When handling off-centered loads that cannot be centered. S TOWING is approved OFF-ROAD ONLY. Always follow these precautions when hauling cargo.SAFETY Hauling Cargo and Towing WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. S TOWING SPEED should never exceed 16 km/h. S When operating over rough or hilly terrain. Always attach the tow load to the hitch point designated for your vehicle. S OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. S USE EXTREME CAUTION when operating with loads that extend over the rack sides. Carrying a load high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. S SECURE ALL LOADS BEFORE OPERATING. Never exceed 8 km/h when towing loads in rough terrain.

Operating a Quadricycle/trailer combination on public roads is prohibited.6 kg 37 .Hauling Cargo and Towing Load Distribution SAFETY 2/3 1/3 Towing Towing is approved OFF-ROAD ONLY. Do not exceed the maximum capacities when towing. Do not tow any trailer on a grade steeper than 15°. Maximum Towed Load (Level Ground) 386 kg Maximum Vertical Hitch Weight 38.

Start the engine. Contact your dealer for repair if throttle problems arise. This could result in serious injury or death. causing an interruption to the electrical system and an unexpected engine shut-down during operation. After starting the engine. release the key switch to the POSITION LIGHTS ON position. Check the lever for proper operation before starting the engine. (2) Throttle lever Press the throttle lever to increase engine speed and vehicle movement. Check occasionally during operation. It may contact the gas tank cap when turning. LIGHTS ON position turns the headlights on. Do not start or operate a Quadricycle with sticking or improperly operating throttle controls.FEATURES AND CONTROLS Controls/Instruments (5) (4) (3) (1) (2) (1) Main Switch End all electrical power to the vehicle. Release the lever to reduce engine speed and vehicle movement. 38 . The headlights are not on in this position. WARNING Do not attach a large key fob or key ring to the main switch. WARNING (2) Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.

(4) Light Switch High Beam Low Beam The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position. NOTE: The override switch also allows activation of AWD in reverse if the AWD switch is on. WARNING Activating the override switch with the throttle open and while operating in reverse can cause loss of control. (5) Speedometer Mode/Override Switch (Reverse Speed Limiter) Press the button to toggle through the speedometer display modes (except in reverse). cancel the reverse speed limit function by pressing the override switch before opening the throttle. 39 . Do not activate the override switch while the throttle is open. See page 52.Controls/Instruments (3) Engine Stop Switch OFF RUN FEATURES AND CONTROLS (5) (4) (3) The engine will not start or run when the switch is in the OFF position. To gain additional power while operating in reverse.

Do not modify the ETC system or replace it with other throttle mechanisms. (8) Electronic Throttle Control (ETC) (8) ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever. (7) All Wheel Drive (AWD) Switch See page 45 for AWD operating procedures.FEATURES AND CONTROLS Controls/Instruments (8) (14) (6) (13) (12) (11) (10) (9) (7) (6) Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Quadricycle. WARNING (7) The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. 40 .

Return the toggle to the center position and push it inward to end the signal. See page 57. (14) 41 . Use this feature to alert others of an emergency or other situation requiring caution. (10) Hazard Warning (11) Push the hazard warning (10) (9) switch to cause all turn indicators to flash simultaneously. (14) Rear Brake Lever (13) (12) The brake lever operates the rear brakes only. (11) Choke (if equipped) The choke assists in starting a cold engine.Controls/Instruments FEATURES AND CONTROLS (9) Turn Signal Indicator View certain vehicle functions on the instrument panel. See page 42. (12) Horn Press the horn button to alert others of your presence. (13) Turn Signal Push the toggle switch either left or right to activate the corresponding turn signal. The corresponding lights illuminate when the feature is activated.

42 . Read this owner’s manual and understand the operation of all brake systems on this vehicle. WARNING Aggressively applying the rear brake when backing down a hill may cause rear tipover. If the rear wheels begin to skid or slide while using this brake. Always use caution whenever applying only the rear brakes.FEATURES AND CONTROLS Brakes Foot Brake The all-wheel foot brake is located on the right footrest. Aggressively applying the rear brake while moving forward may cause the rear wheels to skid and result in loss of control. Squeeze the brake lever toward the handlebar to apply the rear brakes. reduce lever pressure. Rear Brake Lever The left brake lever operates the hydraulic rear brakes only. Press the brake pedal down with your foot to engage the all-wheel brakes. The foot brake operates both front and rear brakes.

4. Locking the Parking Brake The hydraulic parking brake lock is a temporary lock. 1 1. This will prevent the lever from returning to the released position. Always check to be sure the parking brake is disengaged before operating. To release the parking brake lock. Do not rely on the hydraulic parking brake when leaving the vehicle unattended. 43 . Move the park brake lock (2) to the locked position.Brakes Parking Brake FEATURES AND CONTROLS WARNING Operating the Quadricycle while the parking brake is engaged could result in an accident and serious injury or death. Squeeze the left brake lever (1). 3. The parking brake will release automatically. squeeze and release the brake lever. 2 2. Place the transmission in PARK. Always place the transmission in PARK.

The lock must be replaced if the keys are lost. Reverse the procedure to unlock the steering. 4. 44 . 1. Insert the steering lock key and turn it clockwise. 2. 3. Remove the key.FEATURES AND CONTROLS Steering Lock Lock the steering to prevent unauthorized use or theft of the vehicle. NOTE: Place the steering lock keys in a safe place. Turn the handlebars to the full left position.

The front gearcase automatically engages when the rear wheels lose traction. 45 . AWD When the AWD switch is on. There is no limit to the length of time the vehicle may remain in AWD. CAUTION Switching to AWD while the rear wheels are spinning may cause drive shaft and gearcase damage. If the switch is turned off while the front gearcase is engaged. AWD will not engage until engine speed is below 3100 RPM. When the rear wheels regain traction. 2X4 When the 2X4 switch is on.AWD Operation FEATURES AND CONTROLS The AWD switch may be turned on or off while the vehicle is moving. the Quadricycle is in two-wheel drive at all times and the differential is locked. it will not disengage until the rear wheels regain traction. NOTE: The override switch allows activation of AWD in reverse if the AWD switch is on. providing maximum traction. If the rear wheels are spinning. the Quadricycle is in four-wheel drive and the differential is locked. release the throttle before switching to AWD. See page 39. Engage AWD before getting into situations where maximum traction is needed. Switch to AWD while the rear wheels have traction or are at rest. the front gearcase automatically disengages. AWD remains engaged until the switch is turned off.

S If gasoline spills on your skin or clothing. Refuel outdoors or in a well ventilated area. S Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored. S Do not overfill the tank. Static electricity between the rack and container could cause a spark. immediately wash it off with soap and water and change clothing. S Refuel with the engine stopped. 46 . S Turn the fuel valve off (if equipped) whenever the vehicle is stored or parked. S Never fill a fuel container while it’s on the vehicle.FEATURES AND CONTROLS Fuel Safety WARNING S Gasoline is highly flammable and explosive under certain conditions. Do not fill the tank neck. S Use extreme caution whenever handling gasoline.

ON: Not used on this model.Fuel Tank FEATURES AND CONTROLS The fuel tank filler cap is located directly below the handlebar. Refuel with either leaded or unleaded gasoline with a minimum of 87 octane. RES: For normal operation. Fuel Valve (if equipped) The fuel valve is located on the bottom of the fuel tank. Do not attempt to clean the fuel filter. The gauge in the cap shows the approximate amount of fuel remaining. 47 . OFF: For vehicle storage and when transporting. Access the fuel valve through the right front wheel well. Fuel Filter (EFI) The in-line fuel filter should be replaced by your dealer after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris. NOTE: This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition.

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park P R N L H CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving can cause transmission damage. 48 . The transmission is locked when it’s in PARK. use low forward gear in heavy pulling situations and when operating at less than 11 km/h for extended periods of time. Whenever the vehicle is left unattended.FEATURES AND CONTROLS Transmission Gear Selector The transmission gear selector is located on the right side of the vehicle. If towing the vehicle is necessary. Stop the vehicle. shift the transmission into neutral for better mobility and to prevent damage to the belt. See your dealer if you experience any shifting problems. Belt Life To extend belt life. release the throttle and move the shift lever to the desired gear. place the transmission in PARK.

CAUTION Extending the starter rope too far will cause damage to the recoil assembly. especially when traveling in wet areas. use the recoil starter (1). cranking the engine with the recoil starter instead of the main key switch. 1. 49 . Grasp the recoil starter rope handle tightly. water may enter the recoil housing and damage components. Pull the rope abruptly to start the engine. Make sure the handle is fully seated on the recoil housing. Do not extend the starter rope so far that it stops.Recoil Starter (if equipped) FEATURES AND CONTROLS If the battery is too weak to start the engine. Follow the starting procedures on pages 57 and 59. Pull slightly 1 until the starter mechanism engages. 2. If the starter rope handle is not seated properly.

Rider Information Center 2. 50 . High Beam Indicator 6. It measures distance as well as hours of operation. Hot Engine Indicator CAUTION To prevent damage to the instrument cluster. Neutral Indicator 3. Speedometer 5.) 4. Speedometer needle (In addition to showing vehicle speed. wash the Quadricycle by hand or with a garden hose using mild soap. the needle flashes when a warning condition exists. See page 39 for additional information. 4 3 5 2 6 1 1. Immediately wash off any gasoline that splashes on the instrument cluster.FEATURES AND CONTROLS Instrument Cluster The instrument cluster senses vehicle speed from the right front wheel. Do not use alcohol to clean the instrument cluster. It also includes a reverse speed limiter function that limits reverse speed to about 11-14 km/h.

6.5 seconds at start-up. Drive at a higher RPM or recharge the battery to clear the warning. take the Quadricycle to your Polaris dealer. accessories) is applied. 8.“HOT” will display when the engine is overheating. The warning may also occur if the engine is at idle and a high electrical load (lights.This warning usually indicates that the vehicle is being operated at an RPM too low to keep the battery charged. 4 5 6 H = High Range 3 L = Low Range 7 N = Neutral R = Reverse 2 P = Park 2.This indicator illuminates when the electrical portion of the AWD system is enabled. Odometer/Tachometer/Tripmeter/ Hour Meter 7. Check Engine Warning Indicator . NOTE: If the instrument cluster fails to illuminate. Mode Indicator 8 1 51 . 1. AWD Indicator . Service Interval/Diagnostic Mode Indicator 5. cooling fan. All segments will light up for 2. Gear Indicator . Turn off the engine or serious damage could result. 3. a battery over-voltage condition may have caused it to shut down to protect the electrical system. If this occurs. Low Battery and Over-Voltage .As the shift lever is moved. this indicator shows the gear the transmission is in.Instrument Cluster FEATURES AND CONTROLS Rider Information Center The rider information center is located in the instrument cluster. Engine Hour Display Indicator 4.

Mode 2 -Trip Meter The trip meter records the distance traveled on each trip if it’s reset before each trip. Use the mode button to toggle through the four (4) standard modes of the rider information center. Mode 4 . To reset the trip meter. Mode 3 . Press and hold the mode button (override button) until the total changes to 0.Hour Meter The hour meter logs the total hours the engine has been in operation.Odometer The odometer records the total distance traveled by the vehicle since manufacture. NOTE: The trip meter displays a decimal point. select the trip meter mode. Mode 1 .FEATURES AND CONTROLS Instrument Cluster Rider Information Center The reverse override button on the left handlebar is also the mode button.Tachometer The tachometer displays engine RPM. 52 . but the odometer does not. NOTE: The transmission cannot be in reverse. Small fluctuations in the RPM are normal due to changes in humidity. temperature and elevation.

S Turn the main key switch off and on. 2. 3.Instrument Cluster FEATURES AND CONTROLS Rider Information Center Diagnostic Mode The diagnostic mode is for informational purposes only. Turn the main key switch off and wait 10 seconds. The wrench icon will display when the gauge is in the diagnostic mode. Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the gear switch input. Three (3) ways to leave the diagnostic mode: S Shift the transmission out of neutral. Use the mode button to toggle through the six (6) diagnostic screens. S Move the tires. Please return your Quadricycle to your dealer for all major repairs. Screen 1: Battery voltage Screen 2: Tachometer Screen 3: AWD diagnostic This screen indicates whether or not current is flowing through the AWD system. 53 . 4. 5. Hold the mode button and turn the main key switch on. Steps to enter the diagnostic mode: 1. Shift the transmission into neutral or park. Release the switch as soon as the display is activated.

2. You must enable the programmable service interval before it can be used. When set. Press and hold the mode button for approximately seven (7) seconds. Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display either kilometers or miles. the hours of operation are subtracted from the set hours until 0 is reached. 1. NOTE: If you scroll past the intended number. When the wrench stops flashing. You can then reset the number. the mode has been set. 2. The service interval is disabled when the word OFF displays. The current display mode will be shown as either KM or MP. The wrench icon will flash quickly for five seconds each time the engine is started as a reminder that service is due. Press and release the mode button once. 3. Press and hold the mode button until the letters flash. This feature is pre-set at 50 hours. When the display stops flashing. Disabling the Service Interval 1. hold the button down until the count turns over to 0. Press and hold the button to advance the hours at a faster pace. When the desired time increment is displayed. Release the button. 54 . service hours are set. release the button.FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Screen 5: Programmable service interval The programmable service interval provides a convenient reminder when routine maintenance is due. Press and hold the mode/override button until the wrench icon flashes. Toggle to the service interval mode. Press the button once to advance the setting by one hour. 2. Setting the Service Interval 1.

Perform regular checks on fluid levels. See page 56. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Pull only light loads. Drive slowly. or the time it takes to use the first two full tanks of gasoline. Fill the fuel tank with the recommended fuel. 4. controls and areas outlined on the daily pre-ride inspection checklist. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. 55 . Avoid aggressive acceleration and high speed operation during the break-in period. No single action on your part will increase the life and performance of your Quadricycle more than following the procedures for a proper break-in. Check the oil level on the dipstick. Add oil if necessary. 3. Do not operate at sustained idle. 7.Break-In Period OPERATION The break-in period for your new Polaris Quadricycle is the first ten hours of operation. Vary throttle positions. Pull only light loads. Engine and Drivetrain Break-in 1. PVT Break-in (Clutches/Belt) Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. See page 69. Perform the break-in oil change at one month. 2. 5. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 6.

112 89 -47. goggles. protective clothing See Page 82 80 42 67 67 -90. ensure tightness Ensure proper levels Ensure proper operation Ensure operation Ensure proper operation Inspect.OPERATION Pre-Ride Inspection Pre-Ride Checklist Item Brake system / lever travel Brake fluid Foot brake Front suspension Rear suspension Steering Tires Wheels / fasteners Frame nuts. 69 38. apply Polaris dielectric grease when lamp is replaced Wear helmet. apply Polaris dielectric grease when lamp is replaced Check operation. lubricate if necessary Ensure free operation Inspect condition and pressure Inspect. pre-filter Air box sediment tube Headlamp Brake light / tail lamp Riding gear Remarks Ensure proper operation Ensure proper level Ensure proper operation Inspect. ensure fastener tightness Inspect. 86 38 39 91 -92 93 22 56 . bolts. lubricate if necessary Inspect. clean Drain deposits whenever visible Check operation. fasteners Fuel and oil Throttle Indicator lights / switches Engine stop switch Air filter.

Starting the Engine Starting a Cold Engine OPERATION WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in serious injury or death. P R N L H FULL ON HALF ON OFF NOTE: If the engine slows or stops after starting. 1. Never run an engine in an enclosed area or indoors. Excess fuel washing into the engine oil will increase wear on engine components. Pull the choke knob out until it stops. NOTE: Make sure the choke is off during operation. push the choke all the way in. CAUTION Operating the vehicle immediately after starting could cause engine damage. Vary engine RPM slightly with the throttle. position the choke knob half way in. 4. Allow the engine to warm up for several minutes before operating. 2. Sportsman 500 (Carbureted Model) 3. Position the vehicle on a level surface. When the engine idles smoothly. Place the transmission in PARK. 57 . Turn the fuel valve to “RES”.

NOTE: Do not press the throttle while starting the engine. Activate the starter for a maximum of five seconds. Turn the ignition key past the ON position to engage the starter. 6. 8. If the engine does not start. Move the engine stop switch to RUN. 7. Repeat steps 6 and 7 until the engine starts.OPERATION Starting the Engine Starting a Cold Engine All Models 5. release the starter and wait five seconds. 58 . releasing the key when the engine starts.

Any condensation must be drained. 59 . which can lead to engine damage. 4. check the oil level frequently. change the spark plug and try again. intermittent use of the choke (pulled half way out) may be necessary. Start a warm engine using the same procedure for starting a cold engine. A rising oil level could indicate condensation in the bottom of the oil tank. NOTE: If the engine has cooled and does not readily start. Release the throttle lever immediately after the engine starts. 3. If the engine does not start and all conditions are favorable. 1. Always operate the engine long enough to reach operating temperature. which provide quicker warm-ups and easier starting in cold weather. If the engine is over-choked when warm. 2.Starting the Engine OPERATION Starting a Warm Engine (Carbureted Models) Warm engines do not normally require the use of the choke. push in the choke and depress the throttle lever fully while cranking. Over-using the choke can cause spark plug fouling. If the vehicle is used year-round. which reduces condensation. See your Polaris dealer for engine heater kits. Cold Weather Operation for 4-Cycle Engines Internal engine condensation increases as outside temperatures decrease. See page 57. but do not use the choke.

OPERATION Polaris Variable Transmission Preventing Belt Slip / Failure Belt slip creates heat that destroys belts and causes outer clutch covers to fail. The air temperature in the clutch cover will be greatly reduced.). increasing the life of the PVT components (belt. mountains.) at slow speeds S Driving on pavement Use high range for: S Driving off road at faster speeds 60 . etc. Switch to low range when operating at slow speeds. etc. When To Use Low Range and High Range Use low range for: S Heavy pulling S Driving in rough terrain (swamps. cover.

you have the following responsibilities to make sure this system remains safe: S Always follow all recommended maintenance procedures.PVT System OPERATION WARNING Do not modify any component of the PVT system. Remove the drain plug. 3. 4. S This PVT system is intended for use on Polaris products only. as the owner. S Always make sure the PVT housing is securely in place during operation. Do not install it in any other product. Test for belt slippage. Extensive engineering and testing has been conducted to ensure the safety of this product. Do not hold the throttle wide open. 5. Drain the water. Any modification will cause the system to be out of balance. then shift the transmission to the lowest available range. PVT Drying If water is ingested into the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. Allow the engine RPM to return to idle speed. dry it before operating the vehicle. Reinstall the drain plug. See your dealer as outlined in the owner’s manual. repeat the process. Place the transmission in PARK. The PVT system rotates at high speeds. creating large amounts of force on clutch components. 61 . 2. Take the vehicle to your dealer for service promptly. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. The PVT system has been precision balanced. However. If the belt slips. creating vibration and additional loads on components. 1. Start the engine.

EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor
Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System
The emissions from the exhaust of this vehicle are controlled by engine design, including factory-set fuel delivery and ignition. The engine and related components must be maintained at Polaris specifications to achieve optimal performance. Adjustment to engine idle is the only adjustment recommended that the operator perform. Any other adjustments should be performed by an authorized Polaris dealer.

Electromagnetic Interference
This spark ignition system complies with USA requirements, Canadian ICES-002 and European directives 89/336/EEC and 97/24/EC.

62

Periodic Maintenance Chart

MAINTENANCE AND LUBRICATION

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently. The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 54. Record maintenance and service in the Maintenance Log beginning on page 121.
NOTE: Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Severe Use Definition S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

Maintenance Chart Key
"

E
J

Perform these procedures more frequently for vehicles subjected to severe use. Emission-related service Have an authorized Polaris dealer perform these services.

WARNING
Improperly performing the procedures marked with a J could result in component failure and lead to serious injury or death. Have an authorized Polaris dealer perform these services.

63

MAINTENANCE AND LUBRICATION
Periodic Maintenance Chart
Perform all services at whichever maintenance interval is reached first.
Item
(whichever comes first) Hours Calendar Kilometers 10 20 25 25 25 Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Pre-Ride Daily Daily Daily Daily Weekly Weekly Monthly Monthly Monthly Monthly Monthly 100 200 250 250 250 Inspect; clean often; replace as needed Drain deposits when visible Check level daily, change coolant every 2 years Check operation; apply dielectric grease if replacing Inspect; replace as needed Drain water as needed, check often if operating in wet conditions Inspect periodically Check terminals; clean; test Inspect level; change yearly Inspect level; change yearly Inspect level; change yearly

Maintenance Interval

Remarks

J Steering " Front suspension " Rear suspension

Make adjustments as needj ed. ed See Pre Ride Checklist Pre-Ride on page 56.

Tires
" Brake fluid level " Brake lever travel

Brake systems Wheels/fasteners Frame fasteners
" Engine oil level " Air filter, pre-filter

E

" Air box sediment

E tube

Coolant (if applicable) Headlamp/tail lamp
" Air filter,

E main element
Recoil housing (if equipped)
" Brake pad wear J

Battery
" Front gearcase oil

(if equipped) (if equipped)

" Rear gearcase oil " Transmission oil "

Perform these procedures more often for vehicles subjected to severe use. E Emission-related service J Have an authorized Polaris dealer perform these services.

64

Inspect. adjust. lubricate. 65 . replace if necessary Perform a break-in oil change at one month Lubricate all fittings. replace as needed Inspect coolant strength seasonally. replace if necessary Inspect.Periodic Maintenance Chart Item MAINTENANCE AND LUBRICATION (whichever comes first) Hours Calendar Kilometers 25 25 50 50 50 50 50 50 50 50 50 50 50 100 100 100 100 Monthly 1M 3M 6M 6M 6M 6M 6M 6M 6M 6M 6M 6M 6M 6M 12 M 12 M 250 250 500 500 500 500 500 500 500 500 500 500 500 1000 1000 1000 1000 Maintenance Interval Remarks " Engine breather E filter (if equipped) " Engine oil change Inspect. adjust (break-in) " General lubrication Shift Linkage J Steering " Front suspension " Rear suspension Carburetor float bowl (If equipped) J Throttle Cable/ E ETC Switch J Choke cable (if E equipped) E Carburetor air inDrive belt Cooling system (if applicable) take ducts/flange (if equipped) " Engine oil change " Oil filter change " Oil tank vent hose (if equipped) J Valve clearance E " Perform these procedures more often for vehicles subjected to severe use. E Emission-related service J Have an authorized Polaris dealer perform these services. condition Inspect. adjust Lubricate Lubricate Lubricate Drain bowl periodically and prior to storage Inspect. lubricate. etc. replace if necessary Inspect ducts for proper sealing/air leaks Inspect. adjust. cables. pressure test system yearly Perform a break-in oil change at one month Replace with oil change Inspect routing. lubricate. pivots. adjust.

etc. security. replace as needed Change every two years Clean out Adjust as needed Inspect periodically. replace worn parts Inspect. apply dielectric grease to connectors subjected to water. carburetor. mud.MAINTENANCE AND LUBRICATION Periodic Maintenance Chart Item (whichever comes first) Hours Calendar Kilometers 100 12 M 1000) Maintenance Interval Remarks J Fuel system E J Fuel filter E 100 100 100 100 100 100 100 100 12 M 12 M 12 M 12 M 12 M 12 M 12 M 12 M 1000 1000 1000 1000 1000 1000 1000 1000 Check for leaks at tank cap. replace as needed Inspect Inspect for wear. adjust as needed Adjust as needed " Radiator (if applicable) (if applicable) " Cooling hoses " Engine mounts Exhaust muffler/ pipe J Spark plug E E J Ignition Timing " Wiring J Clutches (drive and driven) bearings 100 100 200 300 12 M 12 M 24 M 36 M - 1000 1600 2000 3000 J Front wheel J Brake fluid Spark arrestor E Idle speed J Toe adjustment " Foot brake J Headlight aim " Perform these procedures more often for vehicles subjected to severe use. E Emission-related service J Have an authorized Polaris dealer perform these services. fuel valve. routing. Inspect. clean. clean external surfaces Inspect for leaks Inspect Inspect Inspect. lines. 66 . pump. filter. replace lines every two years Replace yearly Inspect. adjust when parts are replaced Inspect daily.

See page 74. See page 76. Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. (1) (2) 67 . Locate fittings and grease. Locate fittings and grease.Torque Symbol MAINTENANCE AND LUBRICATION =Torque the item as specified. See page 80. Items not listed in the chart should be lubricated at the General Lubrication interval. Item Engine Brakes Transmission Front Gearcase (1) Front Prop Shaft Yoke (2) Ball Joint Lube Polaris Premium 4 Synthetic 0W40 DOT 3 fluid only Premium AGL Synthetic Gearcase Lube Polaris Premium Demand Drive Hub Fluid Premium U-Joint Grease Premium All Season Grease Method See page 68.

Use of another API certified “SH” oil is acceptable as long as it’s 0W-40. Always check and change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. Use only Polaris Premium 4 All Season Synthetic Oil or an API certified 0W-40 “SH” oil. Oil may need to be changed more frequently if Polaris Premium 4 is not used. See page 111 for the part numbers of Polaris products. CAUTION Using a non-recommended oil may cause serious engine damage. 68 . Never substitute or mix oil brands.MAINTENANCE AND LUBRICATION Engine Oil Polaris Premium 4 Synthetic Oil is the only oil recommended for use in this engine.

3. Reinstall the dipstick completely. Remove the dipstick. P R N 5. Start the engine. 6. 7. Position the vehicle on a level surface. Wipe it clean. A 69 . 2. Check the oil level. Add oil as needed to bring the level between the minimum and maximum marks (A). Do not overfill. 8. 4. Place the transmission in PARK. Turn the engine off.Oil Check MAINTENANCE AND LUBRICATION L H 1. Allow it to idle for 30 seconds. Remove the dipstick.

(engine fails to reach operating temperature). Change the oil more often if the vehicle is routinely subjected to: S operation in dusty or wet conditions. 2. the oil pump may lose its prime. 1. S operation when air temperature is below -12° C. S short trips at -12° to -1° C. which could result in engine damage. 3. Do not allow the vehicle to be without oil overnight. CAUTION If the Quadricycle is left without oil in the system for extended periods. Place the transmission in PARK. 4. S Oil filter (P/N 3084963) S Two . Position the vehicle on a level surface. Always replace the oil and filter within a few hours of draining the oil. Turn the engine off. Start the engine. Allow it to idle for two minutes.MAINTENANCE AND LUBRICATION Oil and Filter Change Always change the engine oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 63. P R N L H 70 . Always change the oil filter when changing oil.95 liter bottles of 0W/40 oil 1. Use Polaris-recommended products.

NOTE: Do not over-tighten. Clean the drain plug. 10. MAINTENANCE AND LUBRICATION CAUTION Hot oil may result in serious burns. Reinstall the drain plug with a new sealing washer. Rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. 71 . 6. Maximum torque for the screen fitting is 34 N-m. Reinstall the screen fitting. 13. 7. Clean the fitting. Remove the drain plug.Oil and Filter Change 5. Reinstall the oil line. 8. Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape. =19-23 N-m 9. 11. 12. Do not allow hot oil to contact skin. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. Drain the oil. Remove the screen fitting from the oil tank. Disconnect the lower oil delivery hose. Place a drain pan under the vehicle.

Place towels under the oil filter. turn the filter counterclockwise to remove it. Remove the dipstick. Then stop the engine and inspect for leaks. Reinstall the dipstick. Clean the filter sealing area on the engine. Using an oil filter wrench (A). 21.5 liters initially. 15. 72 . Check the oil level. A Do not overfill. turn it 1/2 turn by hand. Add 1. A small amount of engine oil will remain in the crankcase. 16. 20. After the filter contacts the engine surface. 18. Prime the oil pump using the procedure on page 73. add about 1. Remove the drain plug on the lower right side of the crankcase to drain the oil. A 17.9 liters of 0W/40 oil. 22. Install the new oil filter. 19. Reinstall the drain plug.MAINTENANCE AND LUBRICATION Oil and Filter Change 14. If the sump is not drained. Add oil as needed to bring the level between the minimum and maximum marks (A).

1. If you do not hear air. you should hear a rush of air. Turn the engine off. Repeat the priming procedure. Remove the clamp. B 4. 3. Allow it to idle for 10-20 seconds. If the line is bled properly. between the end of the oil tank vent fitting (A) and the vent line’s pressure relief slit (B). the line was not bled properly. Clamp or pinch off the A vent line approximately 5 cm from the oil tank.Oil and Filter Change Oil Pump Priming MAINTENANCE AND LUBRICATION Prime the oil pump when 5 cm the oil hose connection between the oil tank and pump inlet has been disconnected. indicating that the line is properly primed and ready for operation. 2. 73 . Start the engine.

6. Maintain the level at the bottom of the fill hole threads. =30 N-m N L H P R 74 . Position the vehicle on a level surface. 2. Remove the fill plug. See page 111 for the part numbers of Polaris products. Place the transmission in PARK. 1. 5.MAINTENANCE AND LUBRICATION Transmission Oil Check See page 67 for recommended lubricants. Reinstall the fill plug. Check the oil level. 3. Add fluid as needed. 4.

Transmission Oil Change
1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the fluid into a drain pan. 6. Clean the drain plug. Reinstall the drain plug.
=30 N-m

MAINTENANCE AND LUBRICATION
L H

P

R

N

7. Add 948 ml of the recommended fluid. See page 67. 8. Maintain the level at the bottom of the fill hole threads. 9. Reinstall the fill plug.
=30 N-m

10. Check for leaks.

75

MAINTENANCE AND LUBRICATION
Front Gearcase Oil Check
See page 67 for recommended lubricants. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Maintain the level at the bottom of the fill hole threads. 5. Add the recommended oil as needed. 6. Reinstall the fill plug.
=11-14 N-m
N L H

P

R

76

Front Gearcase Oil Change
1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the fill plug. 4. Remove the drain plug. 5. Drain the fluid into a drain pan. 6. Clean the drain plug. Reinstall the drain plug.
=15 N-m

MAINTENANCE AND LUBRICATION
L H

P

R

N

7. Add 150 ml of the recommended fluid. See page 67. 8. Maintain the level at the bottom of the fill hole threads. 9. Reinstall the fill plug.
=11-14 N-m

150 ml

10. Check for leaks.

77

Add coolant as needed. See page 111 for the part numbers of Polaris products. 4. NOTE: Maintain coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed. 2. Reinstall the side panel. as the system is purging itself of trapped air. 5. Bottle Coolant Level Some coolant level drop on new machines is normal. Add coolant as needed. Add fresh coolant. 3. NOTE: Check the coolant level in the radiator any time the recovery bottle has run dry. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. See page 87. replace the coolant with a fresh mixture of antifreeze and water. Do not dilute with water. View the coolant level. Check the coolant level when the fluid is cool. 1.MAINTENANCE AND LUBRICATION Engine Cooling System Any time the cooling system has been drained for maintenance or repair. 78 . Polaris Premium 60/40 is premixed and ready to use. Drain the cooling system every two years. Remove the left side panel. NOTE: Always follow the manufacturer’s mixing recommendations for the freeze protection required in your area.

7. Remove the radiator pressure cap. Reinstall the pressure cap. View the coolant level.Engine Cooling System Radiator Coolant Level MAINTENANCE AND LUBRICATION WARNING Escaping steam can cause severe burns. 4. NOTE: Use of a non-standard pressure cap will not allow the recovery system to function properly. 6. 1. Contact your dealer for the correct replacement part. 79 . slowly add coolant through the radiator filler neck. 3. Never remove the pressure cap while the engine is warm or hot. Open the access door. Open the front box cover. 5. Secure the access door and box cover. 2. If coolant is not visible.

The moisture causes the boiling temperature of the brake fluid to drop. After opening a bottle of brake fluid. which could cause an accident. meaning it rapidly absorbs moisture from the air. which can lead to early brake fade and the possibility of accident or severe injury.MAINTENANCE AND LUBRICATION Brakes Brake Fluid Check brake fluid levels for both brake systems before each use of the vehicle. always discard any unused portion. Never operate the Quadricycle with spongy-feeling brakes. Always keep brake fluid at an adequate level. which could result in serious injury or death. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not overfill. WARNING Never store or use a partial bottle of brake fluid. Spongy or weak brakes may indicate a fluid leak or low fluid level. Maintain brake fluid at the recommended level. See page 111 for the part numbers of Polaris products. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Do not operate the vehicle with spongy or weak brakes. 80 . If the fluid level is low and the diaphragm is not extended. WARNING An over-full master cylinder may cause brake drag or brake lock-up. the diaphragm extends into the reservoir as fluid level drops. Brake fluid is hygroscopic. If the fluid level is low add DOT 3 brake fluid only. WARNING Operating the Quadricycle with a spongy brake can result in loss of braking. a leak is likely and the diaphragm should be replaced. Under normal operation. The brakes should feel firm when they’re applied. Do not overfill. See your dealer for service.

Position the vehicle on a level surface. Do not overfill. Do not overfill. Full (A): Dark eye Low (B): Clear eye Add the recommended fluid as needed. Maintain the fluid level between the minimum and maximum marks. Master Cylinder (Foot Brake) The reservoir is located near the foot brake. Make sure the handlebars are straight. 1. Do not overfill. 2.Brakes MAINTENANCE AND LUBRICATION Brake Fluid Master Cylinder (Handlebar) The master cylinder is located on the left handlebar. View the fluid level through the indicator window (eye) on the top of the master cylinder. Maintain the fluid level 6 mm below the top edge of the master cylinder. MAX MIN A B 81 .

MAINTENANCE AND LUBRICATION Brakes Brake Check The front and rear brakes are hydraulic disc brakes. Both brake systems are self-adjusting. Check more often if brakes are used heavily during normal operation. Perform the following checks to keep the brake systems in good operating condition. Check the brake pads for wear. 3. Check the brakes for excessive travel or spongy feel. 2. 1. 1 mm 82 . Replace pads when they are worn to 1 mm. Check the security and surface condition of the brake discs. damage or looseness. The handlebar brake is also hydraulic. activated by applying the foot brake. 4. Check the brake systems regularly for fluid leaks.

Set the handlebars in a straight-ahead position. C 3. see your Polaris dealer for service. The frog should always point straight back from the steering post. perpendicular to the rear tires. 1. 2. The recommended toe alignment is 3-6 mm toe out. 4. Tie an elastic string around the stands. NOTE: If you discover improper alignment. B 83 . The rear measurement should be 2 to 3 mm more than the front measurement. Place stands (A) in front of the vehicle.Steering / Suspension Toe Alignment MAINTENANCE AND LUBRICATION WARNING Do not attempt to adjust alignment. Use the following procedure to check the toe alignment of the vehicle. NOTE: The steering frog can be used as an indicator of whether the handlebars are straight. Measure the distance from the string to the rim at the front and rear of the front rim (C). making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in front of the A vehicle (B). All steering adjustments should be performed by an authorized Polaris dealer.

WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars. 3. see your Polaris dealer for service before operating the vehicle. Adjust the handlebars to the desired height. Handlebar Adjustment 1. or see your Polaris dealer for service. =14-17 N-m NOTE: A gap of up to 3 mm should remain at the rear bolts. Torque the rear two bolts last. resulting in loss of control. 4. 84 . Follow the adjustment procedures exactly. Torque the front two bolts first. 2.MAINTENANCE AND LUBRICATION Steering / Suspension Steering Assembly Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found. 5. Remove the upper headlight pod. Loosen the four bolts. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

Place the transmission in gear. 3. are required for operation above 1800 meters. Above 1800 meters the engine air/fuel mixture becomes too rich and the engine loses approximately 3% of its power for each 300 meter increase in elevation. NOTE: Operating the engine with improper jetting can cause poor performance. the carburetor can be adjusted. adjustments to the carburetor and drive system can be made to allow more efficient operation. Jetting is required only when operating below 4 degrees C.Carburetor Idle Adjustment (if equipped) MAINTENANCE AND LUBRICATION IMPORTANT: Your carbureted Polaris vehicle is calibrated at the factory for optimal performance at altitudes ranging from zero to 1800 meters and at temperatures of 4 degrees C. RPM RPM 85 . Although this power cannot be regained. at 1800 meters and lower. Lock the parking brake. available from your Polaris dealer. overheating or engine damage. Operate the engine for about five minutes. 1. P R N 2. See your Polaris dealer for more information about jetting. Adjust the carburetor idle screw clockwise to raise RPM or counterclockwise to lower RPM. or higher. 4. L H If necessary. Optional jets and clutch components. Place the transmission in PARK.

Reinstall the boot(s) to their original position.6-3.6-3. Readjust cable freeplay if this occurs. On the EFI model. rotate the boot to turn the adjuster. Locate the throttle cable adjuster on the handlebar. Sportsman 500 Slide the two boots (B) off the cable adjuster. 4. 6. Tighten the locknut. Expose the cable adjuster (A) as outlined below.2 mm 5.2 mm of freeplay exists at the lever. NOTE: Engine RPM should not increase when steering is turned full left or right. NOTE: Move the throttle lever back and forth while adjusting.MAINTENANCE AND LUBRICATION Throttle Cable Freeplay Adjustment 1. 1. B B B 86 . Sportsman 500 EFI Squeeze the end of the rubber boot (B) and slide it far enough to expose the end of the cable adjuster. Loosen the locknut (C). 2. Turn the adjuster until 1. B A C B B C A 3.

3. MAINTENANCE AND LUBRICATION 2. Reinstall the side panel by reversing the removal procedure. Grasp the rear of the side panel near the rear cab.Side Panel Removal 1. Pull the panel downward and rearward to remove it from the Quadricycle. Remove the seat. 5. With a firm motion. 87 . 4. pull the panel outward to disengage the side panel from the grommet.

3. Use a flat screwdriver or sidecutters to remove the plastic rivets securing the footwell to the fenders. 2.MAINTENANCE AND LUBRICATION Footwell Removal 1. Remove the footwell. 88 . Remove the four screws on the bottom of the footwell.

Install wheels properly. Remove the wheel nuts. 7. Place the transmission in PARK. 1. Carefully remove the jackstands. Position the vehicle on a level surface. Safely place jackstands under the vehicle. Remove the wheel. Always use original equipment size and type when replacing tires. =27 N-m 89 . 9. 3. Loosen the wheel nuts slightly. 8. 10. P R N L H 4. 6. 2. Torque the wheel nuts. Place the wheel on the hub. Install the wheel nuts finger tight. 5.Wheel Removal / Installation MAINTENANCE AND LUBRICATION CAUTION Operating with improperly installed wheels will affect vehicle handling and could cause an accident resulting in serious injury or death.

improperly inflated tires. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster (A) either clockwise or counterclockwise to increase or decrease spring tension. A 90 . Use only original equipment size and type when replacing tires. non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. These services must be performed by an authorized dealer. Make sure the wheels are installed properly. 3 mm WARNING Operating your vehicle with worn tires. Replace tires when the tread depth measures 3 mm or less. NOTE: Accessory springs are available through your Polaris dealer.MAINTENANCE AND LUBRICATION Tires Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less. Wheel and Hub Tightening Wheel hub and bearing tightness and spindle nut retention are critical items. Maintain proper tire pressure as described on the decal on your vehicle and in the specifications section of the owner’s manual beginning on page 112.

Remove the seat. 3. Rinse and air dry. 2. Unlatch the air box clips. Loosen the hose clamp. 91 . Wash the pre-filter in soapy water. Place the transmission in PARK. 8. 6.Air Filter MAINTENANCE AND LUBRICATION L H 1. P R N 4. Remove the filter. 5. 7. Reverse the steps to reinstall all components. Remove the air box cover. NOTE: Replace the filter if needed. Remove the pre-filter from the filter. Position the vehicle on a level surface.

Reverse all steps to reassemble the headlight. 1.MAINTENANCE AND LUBRICATION Lights WARNING Poor lighting can result in loss of control or an accident. 6. 92 . Remove the access panel at the back of the headlight. Open the front rack cover. causing a hot spot that will shorten the life of the lamp. Do not service the headlamps until they’ve cooled. Remove the lamp. do not touch the lamp with bare fingers. Apply dielectric grease to the socket and install a new lamp. 8. Pull the harness plug to disconnect it from the back of the headlight. 5. Remove the rubber cover from the back of the headlight. 4. Place the transmission in PARK. Turn the collar counter-clockwise and carefully remove the collar and socket. Headlight Lamp Replacement When servicing a halogen lamp. Lights become dirty during normal operation. Wash the headlights and tail lights frequently. Oil from your skin leaves a residue. Hot components can cause serious burns to skin. 3. 2. 7. Hold the plastic part of the lamp.

6. Reinstall all components in reverse order. Place the transmission in PARK. 7. Rotate the taillight socket counterclockwise to remove it. Test the lamp for proper operation. 6. Apply dielectric grease to the socket. 5. Rotate the turn signal socket counterclockwise to remove it. Remove the lamp.Lights MAINTENANCE AND LUBRICATION Taillight Lamp Replacement 1. 3. Remove the lamp. Install the new lamp. 4. Test the lamp for proper operation. Reinstall all components in reverse order. 3. 4. Apply dielectric grease to the socket. 5. 7. Install the new lamp. 2. 2. Rear Turn Signal Lamp Replacement 1. 93 . Place the transmission in PARK.

MAINTENANCE AND LUBRICATION Lights Front Turn Signal Lamp Replacement 1. 5. 3. Place the transmission in PARK. Remove the lens attachment screw (A). 4. Rotate the lamp (B) to remove it. Reinstall the lens. Install the new lamp. 2. A B 94 .

Turn the headlight switch to high beam. NOTE: Include rider weight on the seat when measuring. Tighten or loosen the lower headlight screws to adjust the beam upward or downward or to the left or right. 4. 5. Start the engine. The headlight should be approximately 7.6 m x x Headlight Beam Adjustment 5. Observe the headlight aim on the wall. 95 . P R N L H 3. Place the transmission in PARK. Position the vehicle on a level surface.6 meters from a wall.1 cm 1. The most intense part of the headlight beam should be aimed 5. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.Lights MAINTENANCE AND LUBRICATION 7. 2.1 cm below the mark placed on the wall. 6.

96 . NOTE: The tip should not be white. Fouled The insulator tip is black. caused by use of an improper spark plug or incorrect carburetion or throttle body adjustments. Generally.MAINTENANCE AND LUBRICATION Spark Plugs Spark Plug Condition Normal The insulator tip is tan or brown. A damp film covers the firing end. improper use of the choke. the electrodes are not worn. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. There are few combustion deposits. General causes of fouling are excessive oil consumption. There may be a carbon layer over the entire nose. A white insulator tip indicates overheating. or incorrect carburetion or throttle body adjustments.

97 . =24 N-m 6. Replace worn or fouled plugs. 4. Use the spark plug wrench to remove the spark plug. Remove the spark plug cap. 2. Turn the plug counterclockwise to remove it. 3. Inspect the electrodes for wear and carbon buildup. Verify that the gap is at specification before installation.Spark Plugs MAINTENANCE AND LUBRICATION 1. Reinstall the spark plug cap. See page 87. Reinstall the spark plug. 5. Remove the left side panel.

MAINTENANCE AND LUBRICATION Vehicle Immersion CAUTION If the vehicle stops while fully submerged. major engine damage can result if the machine is not thoroughly inspected. 98 . Turn the fuel valve off (if equipped). Drain any water found in the air box. Carbureted models only: Loosen the carburetor drain screw and drain the carburetor. 2. Remove the spark plug. If your vehicle has been totally submerged in water and it’s impossible to have it serviced before further operation. 4. See page 96. 5. 1. Move the vehicle out of the water. 3. perform the following procedure. Take the vehicle to your dealer before starting the engine.

repeat the drying procedure. Turn the fuel valve to “RES” (if equipped). Attempt to start the engine. NOTE: If water has been ingested into the PVT. If necessary. whether you succeed in starting it or not. Have the vehicle serviced by your dealer promptly. 11. 10.Vehicle Immersion MAINTENANCE AND LUBRICATION 6. 8. Engage the starter for only 2-3 seconds. 99 . 7. See page 61. =24 N-m 9. Reinstall the spark plug. Carbureted models only: Tighten the carburetor drain screw. Turn the ignition key past the ON position to engage the starter. follow the procedure for drying out the PVT. Dry the spark plug.

MAINTENANCE AND LUBRICATION
Spark Arrestor
Occasionally, the spark arrestor may accumulate carbon, which can restrict the exhaust if left unattended. Purge the spark arrestor.

WARNING
Allow components to cool sufficiently before servicing. The exhaust system can get extremely hot. Never run the engine in an enclosed area or indoors. Exhaust contains poisonous carbon monoxide gas. Never go under the vehicle while it’s inclined. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.

1. Remove the arrestor clean-out plug from the bottom of the muffler.

2. Place the transmission in PARK. 3. Start the engine.
P R N

L

H

4. Quickly squeeze and release the throttle lever several times to purge carbon from the system.

100

Spark Arrestor

MAINTENANCE AND LUBRICATION

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet. Wear leather gloves for protection. 6. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4.

7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle 30 cm higher than the front. 8. Place the transmission in PARK. 30 cm 9. Block the wheels. 10. Repeat steps 4 to 6 until no more particles are expelled. 11. Turn the engine off. Allow the arrestor to cool. Reinstall the arrestor plug and remove the exhaust outlet cover or plug.

101

MAINTENANCE AND LUBRICATION
Recoil Housing Drain (if equipped)
Always drain the recoil housing (A) after operating the vehicle in wet conditions. Always remove the drain plug before storing the vehicle.
NOTE: Water will enter the recoil housing if the starter handle (B) is disengaged from the rope guide when under water.

B A

1. Place the transmission in PARK.
P R N

L

H

2. Using a wrench, remove the drain screw (C) on the bottom of the recoil housing. 3. Reinstall the screw after draining the housing.
NOTE: Do not open the crankcase drain unless the engine has ingested water. On 4-cycle engines, some engine oil will be lost if the crankcase drain is opened.

C

102

It contains sulfuric acid. Ventilate when charging or using in an enclosed space. WARNING Battery electrolyte is poisonous. Call physician immediately. Antidote: External: Flush with water. Rinse well with tap water and dry off with clean shop towels. away. flame. Internal: Drink large quantities of water or milk. eyes or clothing. Coat the terminals with dielectric grease or petroleum jelly.Battery MAINTENANCE AND LUBRICATION Always keep battery terminals and connections free of corrosion. remove corrosion with a stiff wire brush. KEEP OUT OF REACH OF CHILDREN. Wash with a solution of one tablespoon baking soda and one cup water. Follow with milk of magnesia. Be careful not to allow cleaning solution or tap water into a conventional battery. beaten egg. If cleaning is necessary. 103 . Always shield eyes when working near batteries. cigarettes. Serious burns can result from contact with skin. Batteries produce explosive gases. Keep sparks. etc. or vegetable oil. Eyes: Flush with water for 15 minutes and get prompt medical attention.

3. Place the transmission in PARK. Install the battery vent tube. Always install a fully charged battery. Remove the battery vent tube. When removing the battery. Disconnect the black (negative) battery cable first. 5. 4. always disconnect the negative (black) cable first. NOTE: Battery Installation 1. Disconnect the hold-down strap. Reinstall the battery cover and attach the hold-down strap. Disconnect the red (positive) battery cable next. 5. 3. 2. Battery Removal 1. which could spill electrolyte. Connect and tighten the red (positive) cable first.MAINTENANCE AND LUBRICATION Battery WARNING Improperly connecting or disconnecting battery cables can cause sparks which could result in an explosion. always connect the negative (black) cable last. 7. Remove battery cover. 6. When reinstalling the battery. Verify that cables are properly routed. If electrolyte spills. Lift the battery out of the Quadricycle. 2. Set the battery in the battery holder. 4. Connect and tighten the black (negative) cable next. 6. immediately wash it off with a solution of one tablespoon baking soda and one cup water to prevent damage to the vehicle. 104 . causing serious injury or death. Be careful not to tip the battery sideways.

To refill use only distilled water. Replenishing Battery Fluid Check the battery fluid level often. Power plug leads may need to be bent down so that the battery cover can be installed. dry place. Check battery voltage each month during storage. Verify that it’s fully charged. Tap water contains minerals that are harmful to a battery. Before reusing.Battery MAINTENANCE AND LUBRICATION Battery Storage Whenever the vehicle is not used for a period of three months or more. and store it out of the sun in a cool. The fluid level should be kept between the upper and lower level marks (A). remove the battery from the vehicle. A 105 . take the battery to your dealer for testing and recharging.

High pressure water may damage components. cleaning the upper body first and the lower parts last. brakes and warning labels. transmission seals. Grease all fittings immediately after washing. S Rinse with clean water frequently. S Do not use high pressure water. and allow the vehicle to run for a while to evaporate any water that may have entered the engine or exhaust system. Waxing the Vehicle Unless it has a special finish. body panels. including insect repellants and chemicals.MAINTENANCE AND LUBRICATION Cleaning the Vehicle Keeping the vehicle clean will extend the life of components. contact your Polaris dealer for free replacements. S Use a garden hose and a pail of mild soap and water S Use a professional-type washing mitten. NOTE: If warning and safety labels are damaged. your Quadricycle can be waxed with any non-abrasive automotive paste wax. Use caution when using these products near plastic surfaces. will damage plastic surfaces. If a high pressure wash system must be used. 106 . S Wipe the vehicle dry with a chamois. Do not wax models that have a camouflage finish. exercise extreme care to avoid directing water onto the wheel bearings. CAUTION Some products.

Battery Storage Remove the battery. MAINTENANCE AND LUBRICATION See page 111 for the part numbers of Polaris products. Breather Filter Inspect and clean or replace the breather filter. Fill the fuel tank. Check / Change Fluids Inspect fluid levels and change fluids if necessary. Air Filter / Air Box Inspect and clean (or replace) the pre-cleaner and air filter. Turn the fuel valve off (if equipped). S Front Gearcase S Transmission S Brake Fluid Drain the Recoil Housing (if equipped) See page 102. Clean the air box and drain the sediment tube. (Carbon Clean Plus will reduce the possibility of bacterial growth in the fuel system. 4. 2. 3. Stabilize the Fuel 1.Storing the Vehicle Clean the Vehicle See page 106. 107 . Follow the instructions on the container.) Allow 15-20 minutes of operation for the stabilizer to disperse through the fuel system. See page 91. Make sure that it’s fully charged. Change Oil and Filter Change the oil and filter. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer. Drain the carburetor bowl (if equipped). See page 70.

Store the battery in a cool. which can lead to engine damage. 3.MAINTENANCE AND LUBRICATION Storing the Vehicle Engine Fogging 1. CAUTION Starting the engine during the storage period will disturb the protective oil film. 108 . Remove the spark plug and add 2-3 tablespoons of Premium 4 Synthetic 0W40 engine oil. and will automatically charge the battery if the voltage drops below a pre-determined point. To access the plug hole.265 or greater. Oil will be forced in and around the piston rings and ring lands. Do not use tap water. use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Apply dielectric grease to the terminal bolts and terminals. Check the fluid level monthly. Charge the battery at 1. Torque to 24 Nm. 2. dry place. Apply dielectric grease to the inside of the spark plug cap and install the cap onto the plug. Battery Maintenance Remove the battery and add distilled water to the proper level. which may contain minerals that reduce battery life. Battery Tendert can be left connected during the storage period.4 amps or less until the specific gravity of each cell is 1. Charge can be maintained easily by using Polaris Battery Tendert charger (PN 2871076) or by charging about once a month to make up for normal self-discharge. coating the cylinder with a protective film of fresh oil. 4. Turn the engine over several times. Never start the engine during the storage period. Reinstall the spark plug.

corrosion and oxidation. Using suitable supports under the frame. Do not use plastic or coated materials. Storage Area / Cover 1. raise the vehicle slightly so that the tires are not touching the ground. Be sure the storage area is well ventilated. Cover the machine with an appropriate cover.Storing the Vehicle MAINTENANCE AND LUBRICATION Inspect and Lubricate Inspect all cables and lubricate. 2. Follow lubrication guidelines in the Maintenance Section of the service or owner’s manual to completely grease and lubricate the entire vehicle with Polaris Premium All Season Grease. Engine Anti-Freeze Test engine coolant strength and change if necessary. 3. Make sure tire pressure is at specification. as they do not allow proper ventilation to prevent condensation. Coolant should be replaced every two years. 109 . 4.

3. 110 . Do not attach tie straps to the front A-arm bolt pockets. Attach the FRAME of the vehicle to the transporting unit securely using suitable straps or rope. H P R N L 4. oil cap and seat are installed correctly. Turn the engine off. 1. Be sure the fuel cap. 5. Remove the key to prevent loss during transporting.MAINTENANCE AND LUBRICATION Transporting the Vehicle Follow these procedures when transporting the vehicle. Place the transmission in PARK. 2. Turn the fuel valve off (if equipped).

8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lube (.5 l) Grease / Specialized Lubricants Premium All Season Grease (89 ml cartridge) Premium All Season Grease (414 ml cartridge) Starter Drive Grease Premium U-Joint Lube (89 ml) Premium U-Joint Lube (414 ml) Grease Gun Kit Dielectric Grease (Nyogelt) Chain Lube (185 ml aerosol) Chain Lube (473 ml aerosol) Coolant 60/40 Coolant (3.95 l) Premium AGL Synthetic Gearcase Lube (3. 2870791 2871281 2871844 2873602 2873603 2871653 2872276 2870465 2871654 2872277 2871322 2871423 2871460 2871515 2871551 2871312 2871329 2872073 2872348 2871323 2871534 2872889 2871326 2870652 2870990 2872893 2871956 Description Engine Lubricant Fogging Oil (355 ml Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (.8 l) 60/40 Coolant (.8 l) Premium ATV Angle Drive Fluid (237 ml) Premium ATV Angle Drive Fluid (.POLARIS PRODUCTS Part No.8 liter jug Premium Demand Drive Hub Fluid (237 ml) Premium Demand Drive Hub Fluid (9.95 l) Pump for 3.95 l) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (3.95 l) Additives / Miscellaneous Brake and Clutch Cleaner Carbon Clean Plus (355 ml) Fuel Stabilizer (473 ml) DOT3 Brake Fluid Engine Degreaser LOCTITE 565 Thread Sealant 111 .

/338 kg (500 EFI) 65 in./122 cm 50./16 l (500) 4.2:1 Full Stroke CDI (500) Electronic (500 EFI) 30 BTDC @ 5000 RPM (500) 13 +/./40./81.6 kg) 90 lbs./28.13 gal.6 l (500 EFI) 2 qts.25 gal./81.035 in./331 kg (500) 745 lbs.25 qts./544 kg 1225 lbs.3 cm 11./1./211 cm 48 in./128.5 in./122 cm 48 in./2.6 cm 730 lbs./15.9 mm) Spark Plug / Gap * Based on EU Directive 76/432/EC 112 .13 l EH500PLE137 (500) EH500PLE210 (500 EFI) 498 92 x 75 40 155 X-6M 6MGHI 194-3 2 Turn (Brass plug) 40mm CV Mikuni 260 w (500) 350 w (500 EFI) 10.8 kg 180 lbs.SPECIFICATIONS SPORTSMAN 500 / 500 EFI INT’L Gross Vehicle Weight Towing Rating Unbraked Trailer Towing Capacity* Hitch Tongue Capacity (Off-Road use only) Front Rack/Storage Box Capacity Rear Rack/Storage Box Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Dry Weight Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Engine Displacement Bore x Stroke Pilot Jet (500) Main Jet (500) Needle Jet (500) Jet Needle (500) Pilot Screw (500) Carburetor (500) Alternator Output Compression Ratio Ignition System Ignition Timing 1200 lbs./54 kg (Rear rack weight and tongue weight not to exceed 180 lbs. (0.9 l 2.6 kg 83 in./165 cm 4./556 kg 1786 lbs. (810 kg) 120 lbs.3 BTDC @ 1150 RPM w/Engine warm (500 EFI) NGK BKR6E / .25 in.

12 (5 psi) All-wheel hydraulic disc Rear-wheel hydraulic disc Transmission park lock and hydraulic lock.91/1 16. Rear Foot Brake Hand Brake Parking Brake Front Suspension Rear Suspension Shock Adjustment Headlights Taillights Brakelight Instrument Cluster Dry Sump Automatic PVT (Polaris Variable Transmission) Side Lever (H/L/N/R/P) 23.1 cm) of travel Rear Spring Preload Adjust Hi/Lo 35 w 8.9 w LCD 113 .2” (20.5” (24.82/1 Kenda Bearclaw 25 x 8 .Forward Drive Ratio .30/1 10.12 (5 psi) Kenda Bearclaw 25 x 10 . Front Tire.Front Tire.Low Gear Reduction .Reverse Gear Reduction .SPECIFICATIONS SPORTSMAN 500 / 500 EFI INT’L Lubrication System Driving System Type Shift Type Gear Reduction .26 w 26.49/1 3. all wheel MacPherson Strut with 8.8 cm) of travel Progressive Rate with 9.

SPECIFICATIONS Jetting Chart (500) Altitude Meters (Feet) ( ) AMBIENT TEMPERATURE Below 40° F Below 5° C +40° F and above +5° C and above 0-1800 (0-6000) 1800-3700 (6000-12000) 160 152.5 Clutching Chart (500) Altitude 0-1800 (0-6000) 1800-3700 (6000-12000) Shift Weight 10 WH PN 5630710 10 RH PN 5630709 Drive Clutch Spring Blue/Green PN 7041157 Blue/Green PN 7041157 Driven Clutch Spring Black PN 7041782 Black PN 7041782 Helix and Spring Setting 41-37° PN 5132344 2+2 41-37° PN 5132344 2+2 Meters (Feet) Clutching Chart (500 EFI) Altitude Meters (Feet) ( ) 0-1800 (0-6000) 1800-3700 (6000-12000) Shift Weight 10 WH PN 5630710 10 RH PN 5630709 Drive Clutch Spring Blue/Green PN 7041157 Blue/Green PN 7041157 Driven Clutch Spring White/Yellow PN 7041635 White/Yellow PN 7041635 Helix* EBS PN 5131674 EBS PN 5131674 *EBS models require no helix / spring adjustment 114 .5 155 147.

the throttle should not be held at the full position for more than 10 seconds. The belt will become more flexible and prevent belt burning. times as required. Slow and easy clutch engagement. Poor engine performance. vary the or snow ingestion into the engine RPM from idle to full throttle. Repeat several PVT system. WARNING: Excessive throttle may cause loss of control and vehicle overturn. aggressive throttle application to engage clutch. Starting out going up a steep incline. Use low range only. or dismount the vehicle and perform the K-turn as described on page 30. Stuck in mud or snow. Driving at low RPM or Drive at a higher speed or use low range more frequently. Check for fouled plugs or foreign material in gas tank. Contact your Polaris dealer for inspection of clutch components. 5 to 7 times. Contact your dealer for service. 115 . Climbing over large objects from a stopped position.TROUBLESHOOTING Drive Belt and Cover Problems Possible Cause Solution Driving the vehicle onto a Shift transmission to low range during loading of the pickup or tall trailer in vehicle to prevent belt burning. PVT operating temperatures and longer component life. and carefully use fast. etc. high range. Belt slippage from water Shift the transmission to park. and carefully use fast. use low range. Use low range only. Using the throttle. With the transmission in park. dirt. low ground speed (at The use of low range is highly recommended for cooler approximately 3-7 MPH). Use the throttle quickly and effectively for efficient engagement. Warm the engine at least 5 minutes. Shift the transmission to low range. During this procedure. brief. or carburetor. aggressive throttle application to engage clutch. Utility use/plowing snow. Shift the transmission to low range. Towing/pushing at low RPM/low ground speed. Insufficient warm-up of vehicles exposed to low ambient temperatures. advance the throttle to about 1/8 throttle in short bursts. Clutch malfunction. fuel lines. When starting out on an incline. Clutch seals should be inspected for damage if repeated leaking occurs. WARNING: Excessive throttle may cause loss of control and vehicle overturn.

Pull on the top portion of the screen.TROUBLESHOOTING Contact your Polaris dealer for service if you’re unable to identify solutions using the following charts. verify stop switch is on Immediately see your Polaris dealer Inspect.5 VDC Check all connections and tighten Check all connections and tighten Engine Rotates. Use a garden hose to flush any debris from the radiator fins. replace if necessary Inspect plug(s). Fails to Start Possible Cause Out of fuel Clogged fuel valve or filter Water is present in fuel Fuel valve is turned off (if equipped) Old or non-recommended fuel Fouled or defective spark plug(s) No spark to spark plug Crankcase filled with water or fuel Overuse of choke (if equipped) Clogged fuel filter Low battery voltage Mechanical failure Refuel Inspect and clean or replace Drain the fuel system and refuel Turn the fuel valve to “RES” Replace with new fuel Inspect plug(s). then remove the lower portion. Plugged Radiator 116 . clean and/or replace spark plugs Replace the filter Recharge battery to 12. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency. Engine Does Not Rotate Possible Cause Tripped circuit breaker Low battery voltage Loose battery connections Loose solenoid / starter connections Solution Reset circuit breaker Recharge battery to 12.5 VDC See your Polaris dealer Solution Engine Overheats Possible Cause Debris lodged in screen Solution Remove and clean the screen.

clean the fuel system Replace with recommended fuel Replace filter Inspect and replace (if equipped) See your Polaris dealer Possible Rich Fuel Mixture Cause Overuse of choke (if equipped) Fuel is very high octane Incorrect jetting (if equipped) Solution Inspect. Stalls or Misfires Possible Cause Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel vent line Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Solution Inspect. clean and/or replace spark plugs Replace with lower octane fuel See your Polaris dealer Stopping/starting without adequate warm. clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Replace with new fuel Recharge battery to 12.TROUBLESHOOTING Engine Runs Irregularly.Allow engine to warm up before operatup ing and/or stopping Clogged air filter Inspect and clean or replace Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range Solution Replace with recommended fuel See your Polaris dealer Set gap to specs or replace plugs 117 .5 VDC Inspect and replace (if equipped) Replace with recommended fuel Inspect and clean or replace See your Polaris dealer See your Polaris dealer See your Polaris dealer Possible Lean Fuel Mixture Cause Low or contaminated fuel Low octane fuel Clogged fuel filter Kinked or plugged fuel tank vent line Incorrect jetting (if equipped) Solution Add or change fuel.

clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten Recharge battery / Check charging system Replace with recommended fuel Inspect. clean and/or replace spark plugs Inspect. clean or replace See your Polaris dealer See your Polaris dealer See your Polaris dealer Clean radiator screen and core if equipped Clean engine exterior See your Polaris dealer Solution 118 .TROUBLESHOOTING Engine Backfires Possible Cause Weak spark from spark plugs Incorrect spark plug gap or heat range Old or non-recommended fuel Loose ignition connections Water present in fuel Incorrectly installed spark plug wires Incorrect ignition timing Mechanical failure Solution Inspect. clean and/or replace spark plugs Set gap to specs or replace plugs Replace with new fuel Check all connections and tighten Replace with new fuel See your Polaris dealer See your Polaris dealer See your Polaris dealer Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water present in fuel / old fuel Overuse of choke (if equipped) Fouled or defective spark plugs Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Refuel Inspect and replace (if equipped) Replace with new fuel Inspect.

please contact your dealer immediately. gives a TWO YEAR LIMITED WARRANTY on all components of the Polaris Quadricycle against defects in material or workmanship. or components or products. at Polaris’ exclusive option. chemicals. normal wear and tear. The exclusive remedy for breach of this warranty shall be. Initial dealer preparation and set-up of your vehicle is very important in ensuring troublefree operation. or used for purposes other than for which it was manufactured. so the above limitations or exclusions may not apply to you if inconsistent with controlling state law. OR OTHER TORT OR OTHERWISE. MN 55340. This warranty does not cover the use of unauthorized lubricants. components or the vehicle due to fire. modified. explosions or any other cause beyond Polaris’ control. This warranty also does not cover any Quadricycle that has been altered structurally. stress cracks. WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT. NEGLIGENCE.WARRANTY LIMITED WARRANTY Polaris Industries Inc. the Warranty Registration Form must be completed by your dealer and submitted to Polaris within ten days. This warranty begins on the date of purchase. or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. This warranty does not cover accidental damage. REGISTRATION At the time of sale. Medina. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. neglected. tearing or puncturing of upholstery material. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL. used for racing. CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION. THE PURCHASER MUST COMPLETE A QUADRICYCLE SAFETY TRAINING COURSE PROVIDED BY THE DEALER IN ORDER TO HAVE VALID WARRANTY ON THE QUADRICYCLE. Polaris will record the registration for warranty. or defects in parts. Upon receipt of this registration. corrosion. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage. repair or replacement of any defective materials. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR QUADRICYCLE IS REGISTERED WITH POLARIS. abuse or improper handling. LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties. 2100 Highway 55. 119 .. this warranty does not cover physical damage to paint or finish. In addition. If you have not signed the original registration and received the “customer copy”. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. This warranty is transferrable to another consumer during the warranty period through a Polaris dealer. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be the warranty entitlement. or fuels that are not compatible with the Quadricycle. improperly maintained.

If any of the above terms are void because of state or federal law. you must take it to a Polaris dealer authorized to repair Polaris Quadricycles. 120 . Please work with your dealer to resolve any warranty issues. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. Some states do not allow limitations on how long an implied warranty lasts. This warranty gives you specific legal rights. however. Polaris suggests that you use your original selling dealer. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY). so the above limitation may not apply to you if inconsistent with controlling state law. and you may also have other rights which vary from state to state. HOW TO OBTAIN WARRANTY SERVICE If your Quadricycle requires warranty service. all other warranty terms will remain in effect. you may use any Polaris Servicing Dealer to perform warranty service. Should your dealer require any additional assistance they will contact the appropriate personnel at Polaris.WARRANTY LIMITATIONS OF WARRANTIES AND REMEDIES ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD.

MAINTENANCE LOG Use the following chart to record periodic maintenance. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 121 .

MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 122 .

MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 123 .

. . . . . . . . . 48 Gearcase Oil Change. . . . . . . . . . . . . . . . . . . . . . . . 94 Headlight . . . . . Front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Stabilizer . . 78 Coolant Level. . . . . . . . . . . . 42 Brake. . . . . . . . . . 22 B Battery . . . . . . . . . . . . . . . . . . . . . 38-41 Jetting Chart (500) . . . . . . . . . . . . . . . 106 Clutch Break-in . . . 55 Belt Life . 39 Equipment Modifications . . . . . . 62 Electronic Throttle Control . . . . . . . . . . . 25 Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Headlight Beam Adjustment . . . . . . . . . . . . . . . . . 85 Cargo . . . . 26 Driving Procedures . . . . . . . . . . Front . . . . . . . . . . . . . . . . 48 Brake Fluid . . . . . . . . . . 80-81 Brake Lever . . . . . . . . . . . . . 80-82 Break-In Period . . 114 Cold Weather Operation . . 23 Driving Safely . . . . . . . . . . . . . . . 23-35 Driving Through Water . . . . . . . . . . . . . . . . 42-43. . . . 42 88 47 46 107 47 47 G Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Lights . . 92-95 E Electromagnetic Interference . . . . . . . . . . . . . . . . . 93 Taillight . . . . . . . . . . . . . . . . . 114 Clutching Chart (500) . . . . . Fuel Valve . . . . . 7 91 45 40 E Engine Break-in . . . . . . . . . . . . . . . . . Footwell Removal . . . . . . . . . . . . . . . 98-99 Instrument Cluster . 38-41 Coolant Level. . 108 Engine Stop Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Engine Fogging . . . . . . . . . . . . . . . . Fuel Safety . . . . . 40 Exhaust Emission Control System . . . . . . . . . . . . . . 77 Gearcase Oil Check. . . . . . Foot . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Light Switch . . . . . . . . 107 Belt Break-in . . . 41 Brake. . . 30 L Lamp Replacement Front Turn Signal . . . . . . . . . . . . . . . . 103-105 Battery Fluid . . . . . . . . . . . . . . . . . 60 Horn . . . .INDEX A Age Restriction . . . . . . . . . . Parking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Helmet . . . . . . 62 Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Battery Installation . . . . . . 84 Hauling Cargo . . . . . . 36-37 Cleaning the Vehicle . 104 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 K-Turn . . . . 42 Brakes . . . . . . . . . . . . . . . . . . . . . . . 105. . . . . . . . . . . . . . . 34-35 Driving Uphill . . . . . . . . . . . . 52 D Diagnostic Mode . . . . . . . Fuel Tank . . . AWD Switch . . . . . . . . . . . . . . . . . . 55 Clutching Chart (500 EFI) . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Battery Removal . . . . . . . . . . . . . . . . . . 79 H Handlebar Adjustment . . . Bottle . 8 ETC . 55 F Foot Brake . . . . . . . . . . Rear . . . . . . . 32 Driving in Reverse . Air Filter . . . . 40 Emission Control Systems . . . . . . 92 Rear Turn Signal . . . . . . . . . . . . . . . . 33 Driving on Slippery Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Engine Cooling System . . . . . . . . . . . . . . . 79 Cooling System . . . . . 43 Brake. . . . . . . . . . . . . . . . . . . . . . . . . . 41 Hour Meter . . . . . . . . . . . . . . . . . . . 95 Headlights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28-29 I-J-K Immersion . . . . . . . . . . . . . . . . . . . . . AWD Operation . . 50-54 Instruments . . Fuel Filter . . 36-37 Hazard Warning . . . . . . 22 High Range . . . . . . . . . . 76 C Carburetor . . 53-54 Drivetrain Break-in . . . . . . . . . . . . . . 62 124 . . . . . . . . . . . . . . . . Radiator . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Storing the Vehicle . . . . . . . . . . . . . . . . . . . . 102 Recoil Starter . . . . . . . . . 60 Transmission Oil Change . . . . . . . 90 Tires . . . . . 67 M Main Switch . . . . . . . . . . . . . . . . . 6-17 Override Switch . . . . . . 107-109 Suspension . . 111 Pre Ride Inspection . . . . . . . . . . . . . . . 49 Restrictions . . . . . . . . . . . . 96-97 Specifications . . . . . . . . . . . . . . . . . . . . . . 70-73 Oil Pump Priming . 43 Parking on an Incline . . . . . . . . . . . . . . . . . . . . 22 V Vehicle Identification Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 PVT Drying . . . . . . . . . . . . 115-118 Turn Signal . . . . 62 O Odometer . . . . . . . . . . . . . . . . . . . . . . . . . 67 S Side Panel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Oil Filter Change . . . . . . . . . . . . 67 Towing . . . . . . . . . . . . . . . . . . . . . . 41 Turning Around on a Hill . . . 18-21 Safety Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 PVT Break-in . . . . . . . . 110 Trip Meter . . . . . . . . . 75 Transmission Oil Check . . . . . . . . . . . . . . . . . . . . . 52 Troubleshooting . . . . . . 94 Signal Light. . . . 61 PVT System .INDEX L Load Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Safety Decals and Locations . . . 90 Toe Alignment . . . . . . . . . . . . . . 57-58 Starting a Warm Engine . . . . . . . . . . . . 74 Transporting the Vehicle . . . . . . . 38 63 24 81 81 40 N Noise Emission Control System . . . . . . . . . . 59 Starting the Engine . . . . . . . . . . . 30-31 P Parking Brake . . . . . . . . . . . . . . . . . . . . 73 Oil. . . . . . . . . . . . . 36-37 Transmission . . . . . . . . . 60 Lubrication Recommendations . . . . . . . . . 86 Throttle lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Vehicle Immersion . . . . . . . . . . . . . . Master Cylinder (Handlebar) . . . . . . . . . . . 7 Severe Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63-66 Polaris Products . . . . . . . . 39 T Tachometer . . . 68 Operator Safety . . . . . . . . 90 Wheel Installation . 63 125 . . . . . Front . . . . . . . . . . . . . . . . Master Cylinder (Foot Brake) . . . . . . . 44 Stop Switch . . 57-59 Steering . . . . . . 119-120 Waxing the Vehicle . 90 Recoil Housing . . . . 62. . . . . . . 83 Steering Assembly . . . . 83 Torque Symbol . . . . . . . . . . Maintenance Chart Key . . . . . 52 Oil Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Making Turns . . . . . . . 42 Rear Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Steering Lock . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Spark Arrestor . . . . . . . . . . . . 106 Wheel Hub Tightening . . . . . . . . . . . . . . . . . 38 Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Turn Signal Indicator . . . . . . . . . . . . . . . . . . 27 Signal Light. . . 87 Sidehilling . . . . 60-61 R Rear Brake Lever . . . . . . . . . . . . . 100-101 Spark Plugs . . 70-73 Oil Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Wheel Removal . . . . . . . . . . . . . . . . . . 83 Symbol Identification . . . . . . . . . . . 37 Low Range . . . . . . . . . 93 Throttle Cable Freeplay . . . . . . . . . 98-99 W Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-54 Riding Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Mirrors . . . . . . . . . . . . . . 52 Taillight . . . . . . . . . Engine . . . . . . . . . . . . . . . 35 Periodic Maintenance Chart . . . . . . . . 39 Starting a Cold Engine . . . . . . . . 112-113 Speedometer Mode Switch . . . . . . . . . . . . . . . Rear . . . 8 Rider Information Center . . . . 89 S Safe Riding Gear . . . . . . . . . . . . .

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