CHAPTER 2

MAINTENANCE

Periodic Maintenance Chart . . . . . . . . . . . . . . . . . . . . 2.1-2.2

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.2
Recommended Lubricants and Capacities . . . . . . . 2.3
Lubricant and Maintenance Product Numbers . . . . 2.4
Lubrication Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Front Gearcase Lubrication . . . . . . . . . . . . . . . . . . .
Transmission Lubrication . . . . . . . . . . . . . . . . . . . . . .
2.5-2.7
2.8
2.9
2
Transmission LInkage Adjustment . . . . . . . . . . . . . . 2.10-2.11
Carburetor Adjustments . . . . . . . . . . . . . . . . . . . . . . . 2.12-2.15
Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16-2.17
Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 2.19
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
Coolant System Maintenance . . . . . . . . . . . . . . . . . . 2.21-2.22
Air Filter Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
Air Box Sediment Tube Service . . . . . . . . . . . . . . . . . 2.24
Breather Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
Recoil Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.25
Oil Change/Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26-2.27
Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28-2.29
Steering and Toe Allignment . . . . . . . . . . . . . . . . . . . 2.30-2.32
Front Hub Maintenance . . . . . . . . . . . . . . . . . . . . . . . 2.33
Exhaust System Maintenance . . . . . . . . . . . . . . . . . . 2.34
Brake System Service . . . . . . . . . . . . . . . . . . . . . . . . . 2.35
Drive Chain Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.36-2.37
Suspension Service . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.38
Wheel Removal/Installation . . . . . . . . . . . . . . . . . . . . 2.39
Tire Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.40
 MAINTENANCE

PERIODIC MAINTENANCE CHART

Inspection, adjustment and lubrication intervals of important components is listed in the following chart.
Maintenance intervals are based upon average riding conditions and a vehicle speed of approximately 10 mph.
Inspect, clean, lubricate, adjust or replace parts as necessary. NOTE: Inspection may reveal the need for re-
placement parts. Always use genuine Polaris parts.
CAUTION: Due to the nature of these adjustments, it is recommended that service be performed by an
authorized Polaris dealer.
Vehicles subjected to severe use (operation in wet or dusty areas, low speed heavy load operation, prolonged
idle) should be inspected and serviced more frequently. For engine oil, short trip cold weather riding also consti-
tutes severe use. Pay special attention to oil level. A rise in oil level in cold weather can indicate moisture collect-
ing in the oil tank. Change oil immediately if oil level begins to rise.
E Emission Control System Service (California).
PERIODIC MAINTENANCE - ENGINE
Frequency
(Whichever comes first)
Item Hours Calendar Miles Remarks
(Km)
E Engine Oil - Level/Change 100 hrs 6 months 1000 (1600) Check Level Daily; Break In service at 1 month

E Oil Filter 100 hrs 6 months 1000 (1600) Replace with oil change

E Air Filter - Foam Pre-Cleaner

onditions. Daily Daily Inspect-Clean & oil more often in dirty c

E Air Filter - Main Element Weekly Weekly Inspect - Replace if necessary

 Air Box Sediment Tube - Daily Drain deposits whenever visible
 Engine Breather Filter 20 hrs Monthly 200 (320) Inspect and replace if necessary
 Oil Tank Vent Hose 100 hrs 12 months 1000 (1600) Inspect hose routing /hose condition
E Valve Clearance 100 hrs 12 months 1000 (1600) Inspect/Adjust

E Idle Speed As required As required Adjust

 Throttle Cable / ETC Switch 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Choke (Enricher) Cable 50 hrs 6 months 500 (800) Inspect -Adjust, Lubricate, Replace if necessary
Carburetor Float Bowl 50 hrs 6 months 500 (800) Drain bowl periodically and prior to storage
Carburetor Air Intake Ducts/Flange 50 hrs 6 months 500 (800) Inspect all ducts for proper sealing/air leaks
E Fuel System 100 hrs 12 months 1000 (1600) Check for leaks at tank cap, lines, fuel valve, filter,
pump & carburetor. Replace lines every 2 years.
E Fuel Filter 100 hrs 12 months 1000 (1600) Replace filter annually
Coolant/Level Inspection Daily Daily Replace engine coolant every 2 years
Coolant Strength / Pressure Test 100 hrs 6 months 1000 (1600) Inspect strength seasonally; Pressure test sys-
System tem annually
Radiator 100 hrs 12 months 1000 (1600) Inspect / Clean external surface
Cooling System Hoses 100 hrs 12 months 1000 (1600) Inspect
Engine Mounts 100 hrs 12 months 1000 (1600) Inspect
Drain Recoil Housing Weekly Weekly More often if operating in wet environment
Exhaust Muffler / Pipe 100 hrs 12 months 1000 (1600)
ELECTRICAL
E Spark Plug 100 hrs 12 months 1000 (1600) Inspect - Replace if necessary
Ignition Timing 100 hrs 12 months 1000 (1600) Inspect
Battery 20 hrs Monthly 200 (320) Check terminals; Clean; Check fluid level
Headlight Aim As required As required Adjust if Necessary
Headlamp Inspection Daily Daily Check operation daily; Apply Nyogel Grease
to connector when lamp is replaced
Tail Lamp Inspection Daily Daily Check Operation Daily; Apply Nyogel Grease
to socket when lamp is replaced

2.1
MAINTENANCE

PERIODIC MAINTENANCE CHART, CONT.

CHASSIS
Frequency
(Whichever comes first)
Item Hours Calendar Miles Remarks
(Km)
 General Lubrication 50 hrs 3 months 500 (800) Lubricate All Fittings, Pivots, Cables, Etc.
 Front Hubs/Fluid Check 50 hrs 6 months 500 (800) Check monthly
 Front Hubs/Fluid Change 100 hrs 12 months 1000 (1600) Check monthly
 Front Hub Spindle Nut Torque Annually 12 months Inspect Torque and Locking Fastener and re-
place if necessary
Drive Belt 50 hrs 6 months 500 (800) Inspect - Adjust, Replace if Necessary
Clutches (Drive And Driven) 100 hrs 12 months 1000 (1600) Inspect, Clean
 Transmission Oil Level 25 hrs Monthly 250 (400) Inspect Monthly; Change Annually
Shift Linkage 50 hrs 6 months 500 (800) Inspect,Lubricate, Adjust
 Steering 50 hrs 6 months 500 (800) Inspect Daily, Lubricate
 Toe Adjustment As required As required Periodic Inspection, Adjust When Parts are Re-
placed
 Rear Axle 50 hrs 6 months 500 (800) Inspect Bearings, Grease Fitting
 Front Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate
 Rear Suspension 50 hrs 6 months 500 (800) Inspect - Lubricate
Drive Chain 50 hrs 6 months 500 (800) Inspect Daily, Adjust and Lubricate if Needed
Tires Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item
 Brake Fluid 200 hrs 24 months 2000 (3200) Change Every Two Years
 Brake Fluid Level Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item
 Brake Lever Travel Pre-ride Pre-ride Inspect Daily, Pre-Ride Inspection Item
 Brake Pad Wear 10 hrs Monthly 100 (160) Inspect Periodically
Auxiliary Brake Adjustment As required As required Inspect Deflection Daily; Adjust
Output Shaft Bearing Monthly Monthly Grease Monthly
Brake System Pre-ride Pre-ride Pre-Ride Inspection Item
Wheels Pre-ride Pre-ride Pre-Ride Inspection Item
Frame Nuts, Bolts, Fasteners Pre-ride Pre-ride Pre-Ride Inspection Item

PRE-RIDE / DAILY INSPECTION

Perform the following pre-ride inspection daily, and when servicing the vehicle at each scheduled maintenance.
 Tires - check condition and pressures
 Fuel and oil tanks - fill both tanks to their proper level; Do not overfill oil tank
 All brakes - check operation and adjustment (includes auxiliary brake)
 Throttle - check for free operation and closing
 Headlight/Taillight/Brakelight - check operation of all indicator lights and switches
 Engine stop switch - check for proper function
 Wheels - check for tightness of wheel nuts and axle nuts; check to be sure axle nuts are se-
cured by cotter pins
 Drive chain - condition and slack; refer to drive chain adjustment
 Air cleaner element - check for dirt; clean or replace
 Steering - check for free operation noting any unusual looseness in any area
 Loose parts - visually inspect vehicle for any damaged or loose nuts, bolts or fasteners
 Engine coolant - check for proper level at the recovery bottle

2.2
 MAINTENANCE

RECOMMENDED LUBRICANTS - QUICK REFERENCE

LUBRICANTS AND MAINTENANCE PRODUCT PART NUMBERS ARE LISTED ON PAGE 2.4. REFER
TO SPECIFICATIONS CHAPTER 1 FOR CAPACITY INFORMATION.

Item Type Notes See

Pages
Engine Oil Polaris Premium 4 Add to proper level on dipstick. 2.26-2.27
Synthetic, 0W/40
Transmission Polaris Synthetic Gear Refer to procedures outlined later in this 2.9
Case Lubricant chapter.
Front Gear Case Premium Front Gearcase Refer to procedures outlined later in this 2.8
Fluid or GL5 80-90 Gear chapter.
Lube
Gear Shift Selector Polaris 0W/40 Synthetic Oil in selector box should be at the center 8.4
Box Engine Lubricant or line of the shift selector plungers. Do not
10W Motor Oil overfill or the selector may hydro-lock.
Coolant Level Polaris Premium 60/40 Fill reservoir tank to full line. Add if neces- 2.22
Pre-mixed Antifreeze/ sary. If reservoir was empty or extremely
Coolant or a 50/50 mixture low, allow engine and cooling system to
high quality antifreeze/ cool completely and check level in radia-
coolant and distilled water tor. Fill to top of filler neck.
Front Hubs Premium Demand Drive Fill hub at 4:00 or 8:00 position until fluid 2.33
Hub Fluid trickles out. Do not force fluid into hub.
Brake Fluid Polaris DOT 3 Brake Fluid -Fill between “Min” & “Max” indicators on 2.35
plastic reservoir.

COLD WEATHER KITS FOR 4 CYCLE ATVS

Oil Tank Cover – PN 287187

Engine Heater – PN 2871507
Oil Tank Heater – PN 2871873

2.3
MAINTENANCE

POLARIS PREMIUM LUBRICANT AND MAINTENANCE PROD-

UCT PART NUMBERS
Part No. Description
Engine Lubricant
2870791 Fogging Oil
2871281 Engine Oil (Quart) Premium 4 Synthetic 0-W40 (4-Cycle)
2871567 Engine Oil (16 Gallon) Premium 4 Synthetic 0-W40 (4-Cycle)
Gearcase / Transmission Lubricants
2871477 Premium Synthetic Gearcase Lubricant (1 Gal.)
2871478 Premium Synthetic Gearcase Lubricant (12 oz.. bottle)
2870465 Oil Pump for Gearcase Oil
2871653 Premium Front Gearcase Fluid (12 oz..)
Grease / Specialized Lubricants
2871322 Premium All Season Grease (3 oz.. cartridge)
2871423 Premium All Season Grease (14 oz.. cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz..)
2871551 Premium U-Joint Lube (14 oz..)
2871312 Grease Gun Kit
1350046 CV Joint Grease Pack (30g)
1350047 CV Joint Grease Pack 50g
2871329 Dielectric Grease (Nyogel)
2871654 Premium Demand Drive Hub Fluid (12 oz..)
Coolant
2871323 60/40 Coolant Gallon
2871534 60/40 Coolant Quart
Additives / Sealants / Thread Locking Agents / Misc.
2870585 Loctite Primer N, Aerosol, 25g
2871949 Loctite Threadlock 242 (50ml.)
2871950 Loctite Threadlock 242 (6ml.)
2871951 Loctite Threadlock 262 (50ml.)
2871952 Loctite Threadlock 262 (6ml.)
2871953 Loctite Threadlock 271 (6ml.)
2871954 Loctite Threadlock 271 (36ml.)
2870584 Loctite RC 680-Retaining Compound (10ml. )
2870587 Loctite 518 Gasket Eliminator / Flange Sealant (50ml.)
2871326 Premium Carbon Clean 12 oz..
2870652 Fuel Stabilizer 16 oz..
2871957 Black RTV Silicone Sealer (3 oz.. tube)
2871958 Black RTV Silicone Sealer (11 oz.. cartridge)
8560054 Marine Grade Silicone Sealer (14 oz.. cartridge)
2870990 DOT3 Brake Fluid
2872113 Disc Brake Quiet, Aerosol, (9 oz..)
2871557 Crankcase Sealant, 3-Bond 1215

2.4
 MAINTENANCE

LUBRICATION

Ill. Item Lube Rec. Method Frequency*

#
1 Engine Oil Polaris 0W/40 Add oil to proper level. Change after 1st month, 6 months or 100
Synthetic hours thereafter; Change more often (25-50
hours) in extremely dirty conditions, or short
trip cold weather operation.
2 Transmission Polaris Synthet- Add to bottom of fill hole. Change annually 
ic Gear Case Approx. 27 oz.. at change
Lubricant
3 Brake Fluid Polaris DOT 3 Fill master cylinder reservoirs to As required. Change fluid every 2 years.
Brake Fluid 1/4″ (6.4mm) from top, or between
indicated lines. See page 2.35.
4 Drive Chain Polaris Chain Apply to chain link plates and roll- As required*
Lube or O-Ring ers
ers.
5 Middle Chain chain lube
* More often under severe use, such as operated in water or under severe loads.

Dipstick

Filter

1. Engine Oil and Filter 2. Transmission Fill Plug

Master Cylinder
Reservoir Max
Min.

3. Brake Fluid (Left hand Master Cylinder shown)

4. Rear Drive Chain

5. Middle Drive Chain

2.5
MAINTENANCE

LUBRICATION, CONT.

14. Steering Post 13. Tie Rod End 7. Front Prop Shaft 8. Propshaft Yoke
Bushings U-Joint (3 pumps max.)

Lower

6. Front Gear Case Fill Plug

Upper
9. Demand 4 Hubs Fill Plug
4 or 8 O’clock position-
(end view)
10. Front Drive
Axle
U-Joint
12. Front A-Arm
Pivot Shaft
11. Ball Joint

Ill. Item Lube Rec. Method Frequency*

#
6 Front Gearcase Oil GL5 80-90 Weight Add to bottom of fill plug threads. See page 2.8 Annually
Gear Lube
7 U-Joints - Front Premium U-Joint Locate Fittings and Grease Semi-annually
Prop Shaft Grease 
8 Propshaft Yoke Premium U-Joint Locate fittings and grease - 3 pumps maximum Annually
Grease
9 Demand 4 Hubs Polaris Demand Remove filler hole screw in hubs. Rotate wheels to Semi-annually
Drive Hub Fluid or 4 or 8 O’clock position. If lubricant is not visible add 
ATF Type F until it flows from filler hole. Reinstall screw.
10 Front Drive Axle “U” Polaris U-Joint Locate grease fitting and grease with grease gun. Semi-annually
Joints Grease 
11 Ball Joint Polaris All Season Locate grease fitting on back side of struts and Semi-annually
Grease grease with grease gun. 
12 Front A-Arm Pivot Polaris All Season Locate grease fitting on pivot shaft and grease with Semi-annually
Shaft Grease grease gun. 
13 Tie Rod Ends Polaris All Season Lift boot. Clean away dirt and grease. Apply fresh Semi-annually
Grease grease by hand and reassemble. 
14 Steering Post Bush- All Season Locate fittings on upper and lower steering post and Semi-annually
ings Grease grease with grease gun. 

* More often under severe use, such as operated in water or under severe loads.
 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy loads)
 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy loads)
 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special

2.6
 MAINTENANCE

LUBRICATION, CONT.

15. Middle Axle Bearings

17. Center Eccentric

16. Swing Arm

Bushings
16. Center Swing
Arm Housing
18. Rear Strut
Stabilizer

15. Rear Axle

Bearing

Ill. Item Lube Rec. Method Frequency*

#
15 Rear and Middle Polaris All Season Locate grease fitting on eccentric and grease with Semi-annually
Axle Bearings Grease grease gun. 
16 Swing Arm Polaris All Season Locate grease fitting on swing arm and grease with Semi-annually
Bushings and Grease grease gun. 
Center Swing Arm
Housing
17 Chain Adjusters Polaris All Season Locate grease fitting on center eccentric and Semi-annually
(Center Grease grease. 
Eccentric)
18 Rear Strut Polaris All Season Locate fitting on rear strut and grease with grease Semi-annually
Grease gun. 
* More often under severe use, such as operated in water or under severe loads.

 Semi-annually or 50 hours of operation (refer to Maintenance Schedule for additional information)

More often under severe conditions (operating in water or hauling heavy loads)

 Annually or 100 hours of operation (refer to Maintenance Schedule for additional information)
More often under severe conditions (operating in water or hauling heavy loads)

 Grease conforming to NLGI No. 2, such as Polaris Premium All Season Grease, Conoco Superlube M or
Mobilegrease Special

2.7
 MAINTENANCE

FRONT GEARCASE LUBRICATION

The gearcase lubricant level should be checked and c
 Be sure vehicle is level before proceeding.
 Check vent hose to be sure it is routed properly and unobstructed.
 The correct gearcase lubricant to use is Polaris Premium GL5 80-90 Gear Lube, or an equivalent lubricant
with a GL5 rating.

FRONT GEARCASE SPECIFICATIONS

Specified Lubricant:
Polaris Front Gearcase Lube PN 2871653
...Or API GL5 80-90 Gearlube

Capacity: . . . . . . . . . . . 4.0 Oz. (120ml.)

Drain Plug / Fill Plug Torque:

14 ft. lbs. (19.4 Nm)

To check the level:

1. The front gearcase lubricant level cannot be
checked with a dipstick or by visual reference. Make sure vent is unobstructed
The gearcase must be drained and re-filled with
the proper amount of lubricant. Refer to procedure
below. Fill plug

To change lubricant:
1. Remove gearcase drain plug located on the bottom
and drain oil. Catch and discard used oil properly.
2. Clean and reinstall drain plug using a new sealing
washer.
3. Remove fill plug.
4. Add proper amount of lubricant.
Drain plug
5. Install fill plug.
6. Check for leaks.

2.8
 MAINTENANCE

TRANSMISSION LUBRICATION
The transmission lubricant level should be checked and c
 Be sure vehicle is level before proceeding.
TRANSMISSION SPECIFICATIONS
 Check vent hose to be sure it is routed properly and
unobstructed. Specified Lubricant:
Polaris Premium Synthetic Gearcase Lubricant
 Follow instructions on following pages to check / PN 2871477 (Gallon) PN 2
change transmission lubricant.
Capacity: . . . . . . . . . . . 27 oz. / 800 ml
To check the level:

1. Remove propshaft shield from the right side of the

Drain Plug / Fill Plug Torque:
vehicle.
14 ft. lbs. (19.4 Nm)
2. Remove fill plug and visually inspect the oil level. Lev-
el is correct when it reaches the bottom of the fill hole
as shown at right.

To change lubricant:

1. Remove propshaft shield from the right side of the

vehicle.

2. Remove transmission drain plug drain the oil. Catch 1 5/8″

and discard used oil properly. Oil Level

3. Clean and reinstall the drain plug with a new sealing

washer. Torque to specification.

4.
871478
Remove
(12 oz..)
fill plug.

5. Add Polaris Premium Synthetic Gearcase Lubricant to

proper level as described above.
View From Front
6. Check for leaks.

7. Reinstall propshaft shield.

Do not fill to bottom

of fill plug threads

View

Transmission Fill Plug

2.9
MAINTENANCE

TRANSMISSION GEARSHIFT LINKAGE ADJUSTMENT, PRE-

LIMINARY INSPECTION
 If shifting problems are encountered, the transmis-
Linkage rod will rotate
sion linkage can be adjusted.
1/8 -1/4 turn if rod ends
are tightened properly.
 Tighten shift linkage rod end jam nuts properly after
adjustment. You should be able to rotate the linkage
rod between 1/8 and 1/4 turn after both jam nuts are
tight.

 The transmission shift linkage should be periodically Parallel

inspected for wear and parts replaced as required to
remove excess play from shift linkage.

 Refer to Transmission chapter for more information. Correctly Tightened Incorrectly Tightened
Jam Nut Jam Nut

SHIFT LINKAGE ADJUSTMENT

Linkage rod adjustment is necessary when symptoms include:
 No All Wheel Drive light
 Noise on deceleration
 Inability to engage a gear
 Excessive gear clash (noise)
 Shift selectors moving out of desired range

NOTE: When adjusting linkage, always adjust both linkage rods. The adjustment of one rod can prevent proper
adjustment of the other rod. Remove necessary components to gain access to shift linkage rod ends (i.e. exhaust
heat shield, exhaust pipe, etc.).

1. Inspect shift linkage tie rod ends, clevis pins, and

pivot bushings and replace if worn or damaged.
Lubricate the tie rod ends with a light aerosol Gear Selector
lubricant or grease. Low Range Slides
Jam
2. Loosen all rod end adjuster jam nuts see Ill. 1. Jam Nut Nut
3. Note orientation of tie rod end studs with stud up or
down. Remove both rod end studs from
transmission bell cranks.

4. Be sure idle speed is adjusted properly.

NOTE: It is important to disconnect both rod ends from

the transmission bell cranks. If one linkage rod is incor- NOTE: Rod end orientation, rod ends are
rectly adjusted, it can affect the adjustment of the other both down.
rod.
Ill. 1

2.10
 MAINTENANCE

SHIFT LINKAGE ADJUSTMENT, CONT.

5. Place gear selector in neutral. Make sure the
transmission bell cranks are engaged in the neutral
position detents.

6. Be sure the shift linkage rod ends are firmly attached

to the gear selector slides. Adjust the low range
(inside) rod so the rod end is centered on the
transmission bell crank. Install the lock nut to the rod
end and torque to 35 in. lbs. Adjust to align linkage rod end studs
with holes in bellcrank(s).

35 in. lbs.

35 in. lbs.

Ill. 2

7. Rotate the linkage rod clockwise until resistance is  Rotate rod both directions to
felt. Mark the rod so revolutions can be easily find points where resistance
counted. See Ill. 3 at right. is felt.
8. Rotate the linkage rod counterclockwise until the  Center the rod between the
same resistance is felt, counting the revolutions as points.
Place
the rod is turned. mark  Hold rod end parallel to
on rod mounting surface and
9. Turn the rod clockwise again one half of the tighten jam nut.
revolutions counted in Step 9.
Parallel
10. Tighten the rod end jam nuts securely while holding
the rod end. The jam nuts must be tightened with
both front and rear rod ends parallel to each other. If
jam nuts are properly tightened, the rod should rotate Ill. 3
freely 1/4 turn without binding.

11. Repeat steps 7-10 for the High/Reverse rod.

2.11
MAINTENANCE

THROTTLE OPERATION
Check for smooth throttle opening and closing in all han-
dlebar positions. Throttle lever operation should be
smooth and lever must return freely without binding.
1. Place the gear selector in neutral.
2. Set parking brake.
3. Start the engine and let it idle.
4. Turn handlebars from full right to full left. If idle speed
increases at any point in the turning range, inspect
throttle cable routing and condition.

5. Replace the throttle cable if worn, kinked, or damaged.

To remove the ETC cover:

2
1. Use a medium flat blade screwdriver and insert blade 3
into the pocket of the cover starting on the #1 1

ÁÁ
position.
2. Twist screwdriver slightly while lifting on the cover to

ÁÁÁÁ
6
release snap.

ÁÁ
5 4
3. Repeat procedure at the other five locations as
shown. NOTE: Do not attempt to remove cover until
all latch points are released.

CHOKE (ENRICHER) ADJUSTMENT

With the choke control toggle flipped to the off position, the Choke Toggle Position
1/8-1/4″ (.3-.6 cm)
choke plunger must be seated on the fuel passage way in Freeplay
the carburetor. If the plunger is not seated on the fuel pas-
sage way inside the carburetor (not enough cable freeplay),
the engine will flood or run too rich, causing plug fouling and Off
poor performance. (Ill 1.)
If cable slack is excessive, the choke fuel passage will not
open far enough, which may cause cold starting difficulty.
Also, the half-choke position used for intermittent applica- Half On
tions will not function properly.

1. Flip choke toggle to off position.

Ill. 1 Full On
2. Slide boots (C) off choke cable adjuster and lock nut (A).
(Ill. 2)
3. Loosen adjustment locknut (A) on cable sleeve on
carburetor.

2.12
 MAINTENANCE

CHOKE (ENRICHER) ADJUSTMENT, CONT.

4. Turn cable sleeve adjusting nut (B) clockwise on
carburetor until 1/4″ (6 mm) or more choke toggle free
play is evident.
B
5. Turn cable sleeve adjusting nut counterclockwise until
toggle has zero free play, then rotate it clockwise until
1/8″-1/4″ (3-6 mm) toggle free play is evident. C

6. Tighten locknut (A).

7. Slide boots back over cable adjuster sleeve until they
touch at the middle point of the sleeve (in-line A
adjusters) or until seated fully over adjuster.

Ill. 2 Adjust at carburetor

Choke Lever Freeplay -

1/8 - 1/4″ (.3 - .6 cm)

PILOT SCREW ANTI-TAMPER PLUG REMOVAL

NOTE: The pilot screw is pre-set at the factory. The following adjustment procedure should be used after carbu-
retor disassembly and cleaning, or if the pilot screw is replaced. Be sure all engine maintenance items have been
performed and are within specifications before adjusting pilot screw. Some models have an anti-tamper plug cov-
ering the pilot screw. If pilot screw adjustment is required, remove it following the procedure outlined below.

1. Remove the carburetor.

2. Drain the carburetor bowl and cover all openings to prevent metal shavings from entering.
3. Invert the carburetor and carefully drill out the center of the plug with a 1/8″ or 5/32″anently
(3 or 4mm) drill bit. Before
drilling, set a drill stop on the shank of the drill bit to prevent drilling beyond 3/16″. CAUTION: Be careful not to drill
into the pilot screw!
4. Drill the plug at slow drill speeds. Use a self-tapping metal screw and a pliers to remove the plug if it does not
rotate out with the drill bit.
5. Turn the screw in until lightly seated. Back out the specified number of turns. This is the pilot screw base
setting. Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be perm
damaged.
Drill Stop
6. Refer to pilot screw adjustment procedure.
Plug
Pilot Screw
Spring
Washer O-Ring
Plug

2.13
MAINTENANCE
anently damaged.

PILOT SCREW ADJUSTMENT

Pilot Screw (Idle Mixture) Adjustment Notes
Do not tighten the pilot screw forcefully against the seat or the screw and/or seat will be perm
Start engine and warm it up to operating temperature (about 10 minutes). This is a very important step.

1. Turn pilot screw in (clockwise) until lightly seated.

Turn screw out the specified number of turns.

Pilot Screw Adjustment:

2.0 Turns
FRONT
(Engine)
2. Connect an accurate tachometer that will read in
increments of + or – 50 RPM such as the PET
2100DX (P/N 8712100DX) or the PET 2500 (P/N
8712500). Pilot Screw
3. Set idle speed to 1200 RPM. Always check throttle
cable freeplay after adjusting idle speed and adjust if
necessary.
4. Slowly turn mixture screw clockwise using the pilot
screw wrench until RPM begins to decrease by 50
RPM or greater.
5. Slowly turn mixture screw counterclockwise until idle
speed increases to maximum RPM. Continue turning
counterclockwise until idle RPM begins to drop.
6. Center the pilot screw between the points in step 5
and 6.
7. Re adjust idle speed if not within specification.

IDLE SPEED ADJUSTMENT

1. Start engine and warm it up thoroughly.
CV Carburetor

2. Adjust idle speed by turning the idle adjustment screw

in (clockwise) to increase or out (counterclockwise) to
decrease RPM. (Refer to Ill. at right).

NOTE: Adjusting the idle speed affects throttle cable

freeplay and electronic throttle control (ETC) adjustment.
Always check throttle cable freeplay after adjusting idle
speed and adjust if necessary.
Idle Screw

Idle Speed:

1200 +/– 200 RPM

2.14
 MAINTENANCE

THROTTLE CABLE / ELECTRONIC THROTTLE

CONTROL (ETC SWITCH) ADJUSTMENT
1. Slide boot off throttle cable adjuster and jam nut.
2. Place shift selector in neutral and set parking brake.
3. Start engine and set idle to specified RPM, then shut
off engine. Boot Adjuster Lock- Boot
Sleeve nut
NOTE: Be sure the engine is at operating temperature.
See Idle Speed Adjustment.

4. Loosen lock nut on in-line cable adjuster (Ill. 1).

5. Turn adjuster until 1/16″ to 1/8″ freeplay is achieved
at thumb lever. (Ill. 2). While making adjustment,
quickly actuate the thumb lever several times.

6. Tighten lock nut securely and slide boot completely in

place to ensure a water-tight seal. Ill. 1

7. Turn handlebars from left to right through the entire

turning range. If idle speed increases, check for
proper cable routing. If cable is routed properly and
in good condition, repeat adjustment procedure.

Direction
of travel
1/16″ - 1/8″
Ill. 2 Freeplay

2.15
MAINTENANCE

FUEL SYSTEM
WARNING

Gasoline is extremely flammable and explosive under certain conditions.

Always stop the engine and refuel outdoors or in a well ventilated area.

Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where
gasoline is stored.

Do not overfill the tank. Do not fill the tank neck.

If you get gasoline in your eyes or if you swallow gasoline, see your doctor immediately.

If you spill gasoline on your skin or clothing, immediately wash it off with soap and water and change clothing.

Never start the engine or let it run in an enclosed area. Gasoline powered engine exhaust fumes are poison-
ous and can cause loss of consciousness and death in a short time.

Never drain the float bowl when the engine is hot. Severe burns may result.

FUEL LINES
1. Check fuel lines for signs of wear, deterioration,
damage or leakage. Replace if necessary.
2. Be sure fuel lines are routed properly and secured with
cable ties. CAUTION: Make sure lines are not kinked
or pinched.
3. Replace all fuel lines every two years.

VENT LINES
1. Check fuel tank, oil tank, carburetor, battery and
transmission vent lines for signs of wear, deterioration,
damage or leakage. Replace every two years.
2. Be sure vent lines are routed properly and secured
with cable ties. CAUTION: Make sure lines are not
kinked or pinched.

FUEL FILTER
The fuel filter should be replaced in accordance with the
Periodic Maintenance Chart or whenever sediment is vis-
ible in the filter.
1. Shut off fuel supply at fuel valve. Arrow Indicates Direction
2. Remove line clamps at both ends of the filter. of Flow
3. Remove fuel lines from filter.
4. Install new filter and clamps onto fuel lines with arrow
pointed in direction of fuel flow.
5. Install clamps on fuel line. To Carburetor
6. Turn fuel valve ON.
7. Start engine and inspect for leaks.
8. Reinstall fuel tank.

2.16
 MAINTENANCE

CARBURETOR DRAINING
The carburetor float bowl should be drained periodically to
remove moisture or sediment from the bowl, or before ex-
tended periods of storage.
NOTE: The bowl drain screw is located on the bottom left
side of the float bowl.

1. Turn fuel valve to the off position. Drain tube

attached
2. Place a clean container beneath the bowl drain spigot here
or bowl drain hose.
Drain Screw
3. Turn drain screw out two turns and allow fuel in the
float bowl and fuel line to drain completely.
RES
4. Inspect the drained fuel for water or sediment.

5. Tighten drain screw.

6. Turn fuel valve to “on”. OFF

7. Start machine and check for leaks.

NOTE: If there is a tube attached, it must be replaced as
this will effect engine performance. ON

2.17
MAINTENANCE

COMPRESSION TEST
NOTE: 4-Stroke engines are equipped with an automatic decompressor. Compression readings will vary in pro-
portion to cranking speed during the test. Average compression (measured) is about 50-90 psi during a compres-
sion test.

Smooth idle generally indicates good compression. Low engine compression is rarely a factor in running condition
problems above idle speed. Abnormally high compression can be caused by a decompressor malfunction, or
worn or damaged exhaust cam lobes. Inspect camshaft and automatic decompression mechanism if compres-
sion is abnormally high.

A cylinder leakage test is the best indication of engine condition on models with automatic decompression. Follow
manufacturer’s instructions to perform a cylinder leakage test. (Never use high pressure leakage tester as crank-
shaft seals may dislodge and leak).

Cylinder Compression
Standard 50-90 PSI

Cylinder Leakage
Service Limit 10 %
(Inspect for cause if leakage exceeds 10%)

ENGINE MOUNTS
Inspect rubber engine mounts (A) for cracks or damage.

A
FASTENER TORQUE - ENGINE
Check engine fasteners and ensure they are tight.

2.18
 MAINTENANCE

BATTERY MAINTENANCE

WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious
burns can result from contact with skin, eyes or clothing. Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician immedi-
ately.
Eyes: Flush with water for 15 minutes and get prompt medical
attention.
Batteries produce explosive gases. Keep sparks, flame, ciga-
rettes, etc. away. Ventilate when charging or using in an enclosed
space. Always shield eyes when working near batteries. KEEP
OUT OF REACH OF CHILDREN.

The battery is located under the left rear fender.

Inspect the battery fluid level. When the battery fluid nears
the lower level, the battery should be removed and distilled
water should be added to the upper level line. To remove
the battery:
1. Disconnect holder strap and remove cover.
2. Disconnect battery negative (-) (black) cable first, Maintain
followed by the positive (+) (red) cable. between upper
and lower level
CAUTION marks

Whenever removing or reinstalling the battery, disconnect

the negative (black) cable first and reinstall the negative
cable last!
3. Disconnect the vent hose.
4. Remove the battery.
5. Remove the filler caps and add distilled water only as needed to bring each cell to the proper level. Do not
overfill the battery. Fully recharge after refilling.

To refill use only distilled water. Tap water contains minerals which are harmful to a battery.

Do not allow cleaning solution or tap water to enter the battery. It will shorten the life of the battery.

6. Reinstall the battery caps.

7. Clean battery cables and terminals with a stiff wire brush. Corrosion can be removed using a solution of one
cup water and one tablespoon baking soda. Rinse well with clean water and dry thoroughly.
8. Reinstall battery, attaching positive (+) (red) cable first and then the negative (-) (black) cable.
9. Reattach vent hose making sure it is properly routed and not kinked or pinched.
10. Coat terminals and bolt threads with Nyogel grease.
11. Reinstall battery cover and holder strap.
NOTE: New Battery: Battery must be fully charged before use or battery life will be significantly reduced 10-30%
of batterys’ full potential.

2.19
MAINTENANCE

SPARK PLUG
1. Remove spark plug high tension lead. Clean plug area
so no dirt and debris can fall into engine when plug is Recommended Spark Plug:
removed.
Refer to Specifications
2. Remove spark plug.
3. Inspect electrodes for wear and carbon buildup. Look
for a sharp outer edge with no rounding or erosion of Spark Plug Torque: 14 Ft. Lbs.
the electrodes. (19 Nm)
4. Clean with electrical contact cleaner or a glass bead
spark plug cleaner only. CAUTION: A wire brush or
coated abrasive should not be used.
5. Measure gap with a wire gauge. Refer to
specifications for proper spark plug type and gap.
Adjust gap if necessary by bending the side electrode
carefully.
6. If necessary, replace spark plug with proper type.
CAUTION: Severe engine damage may occur if the
incorrect spark plug is used.
7. Apply a small amount of anti-seize compound to the
spark plug threads.
8. Install spark plug and torque to 14 ft. lbs. Spark Plug Gap
.024 - .028″ (.6 - .7 mm)
IGNITION TIMING
Refer to Electrical chapter for ignition timing procedure.

Engine-To-Frame Ground
Inspect engine-to-frame ground cable connection. Be
sure it is clean and tight.

2.20
 MAINTENANCE

LIQUID COOLING SYSTEM OVERVIEW

The engine coolant level is controlled or maintained by the recovery system. The recovery system components
are the recovery bottle, radiator filler neck, radiator pressure cap and connecting hose.
As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator
past the pressure cap and into the recovery bottle. As engine coolant temperature decreases the contracting
(cooled) coolant is drawn back up from the tank past the pressure cap and into the radiator.
 Some coolant level drop on new machines is normal as the system is purging itself of trapped air. Observe
coolant levels often during the break-in period.
 Overheating of engine could occur if air is not fully purged from system.
 Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water.

COOLANT STRENGTH / TYPE

Test the strength of the coolant using an antifreeze
hydrometer.

 A 50/50 or 60/40 mixture of antifreeze and distilled wa-

ter will provide the optimum cooling, corrosion protec-
tion, and antifreeze protection.
 Do not use tap water, straight antifreeze, or straight wa-
ter in the system. Tap water contains minerals and im-
purities which build up in the system.
 Straight water or antifreeze may cause the system to Antifreeze Hydrometer
freeze, corrode, or overheat.

Polaris 60/40 Anti-Freeze / Coolant

PN 2871323

COOLING SYSTEM HOSES

1. Inspect all hoses for cracks, deterioration, abrasion or
leaks. Replace if necessary.
2. Check tightness of all hose clamps.

CAUTION:Do not over-tighten hose clamps at radiator, or

radiator fitting may distort, causing a restriction to coolant
flow. Radiator hose clamp torque is 36 inch lbs.

RADIATOR
1. Check radiator air passages for restrictions or
damage.
2. Carefully straighten any bent radiator fins.
3. Remove any obstructions with compressed air or low
pressure water.

COOLING SYSTEM PRESSURE TEST

Refer to page 3.6 for pressure test procedure.

2.21
MAINTENANCE

COOLANT LEVEL INSPECTION

The recovery bottle, located on the left side of the machine,
must be maintained between the minimum and maximum
levels indicated on the recovery bottle.
Recovery
With the engine at operating temperature, the coolant level
Bottle
should be between the upper and lower marks on the
Accessible
coolant reservoir. If not: Under Side
Panel
1. Remove reservoir cap. Inner splash cap vent hole
must be clear and open.

2. Fill reservoir to upper mark with Polaris Premium

60/40 Anti Freeze / Coolant or 50/50 or 60/40 mixture
of antifreeze and distilled water as required for freeze
protection in your area.

3. Reinstall cap.
NOTE: If overheating is evident, allow system to cool
completely and check coolant level in the radiator and in-
spect for signs of trapped air in system.

RADIATOR COOLANT LEVEL INSPECTION

NOTE: This procedure is only required if the cooling sys-
tem has been drained for maintenance and/or repair.
However, if the recovery bottle has run dry, or if overheat- Front
ing is evident, the level in the radiator should be inspected Cover
and coolant added if necessary.

WARNING Never remove the pressure cap when

the engine is warm or hot. Escaping steam can cause se- Rack
vere burns. The engine must be cool before removing the
pressure cap.
NOTE: Use of a non-standard pressure cap will not allow
the recovery system to function properly.
To access the radiator pressure cap:
Remove the four screws securing front rack. Turn handle
bars full left or right to provide more clearance. Remove
front cover by placing your fingers under the front of the
cover and pulling upward.

2.22
 MAINTENANCE

AIR FILTER PRE-FILTER SERVICE

It is recommended that the air filter and pre filter be replaced
annually. When riding in extremely dusty conditions re- Cover
placement will be required more often.
Gasket
The pre filter should be cleaned before each ride, using the
following procedure.
1. Lift up on the rear of the seat. Pre-filter
2. Pull the seat back and free of the tabs. NOTE: When
reinstalling seat, make sure the slots in the seat engage Main Element
the tabs in the fuel tank.
3. Remove clips (6) from air box cover and remove cover.
Inspect the gasket. It should adhere tightly to the cover
and seal all the way around.
4. Loosen clamp and remove air filter assembly.
Cleaning
5. Slip the pre-filter element off of main element. Clean
the pre filter with high flash point solvent, followed by
hot soapy water.
6. Rinse and dry thoroughly.
7. Inspect element for tears or damage.
8. Apply foam filter oil or clean engine oil and squeeze
until excess oil is removed.
9. Inspect main element and replace if necessary. If the
filter has been soaked with fuel or oil it must be
replaced.
Installation
10. Reinstall pre-filter element over main filter. Be sure the
element covers entire surface of main filter without
folds, creases, or gaps.
11. Install air box cover and secure with clips.
NOTE: Apply a small amount of general purpose grease
to the sealing edges of the filter before reinstalling.

8. Reinstall pre-filter in main filter. Replace main filter

as required.

2.23
MAINTENANCE

AIR BOX SEDIMENT TUBE

Periodically check the air box drain tube located toward the
rear of the machine. Drain whenever deposits are visible
in the clear tube.
NOTE: The sediment tube will require more frequent ser-
vice if the vehicle is operated in wet conditions or at high
throttle openings for extended periods.

1. Remove drain plug from end of sediment tube.

2. Drain tube.

3. Reinstall drain plug.

Sediment Tube

BREATHER FILTER INSPECTION

Four cycle ATV engines are equipped with a breather filter.
The in-line filter is similar in appearance to a fuel filter, and
is visible on the left side (Location A).
1. In-line breather filters should be installed with the
arrow pointing toward the engine (away from the air
box).
NOTE: In-line breather filter service life is extended when Typical Breather Filter Location
the foam air box pre-filter is in place and maintained prop-
erly. Never operate the engine without the pre-filter.

BREATHER HOSE
1. Be sure breather line is routed properly and secured in
place. CAUTION: Make sure lines are not kinked or
pinched.

In-Line Breather Filter

Location A

2.24
 MAINTENANCE

RECOIL HOUSING
 Drain the housing periodically to remove moisture.
 Drain the recoil housing after operating the ATV in
very wet conditions. This should also be done before Crankcase Drain
storing the ATV. The drain screw is located at the bot-
tom of the recoil housing. Remove the screw with a
10mm wrench. Reinstall screw once housing has
been drained.
 CAUTION: Make sure the manual start handle is ful-
ly seated on the recoil housing, especially when trav-
elling in wet areas. If it is not sealed properly, water
may enter the recoil housing and damage compo-
nents.
 Water will enter the recoil housing if the starter handle Recoil Drain
is disengaged from the rope guide when under water.
 After travelling in wet areas the recoil housing and
starter should always be drained completely by re-
moving the recoil.
 Do not open the crankcase drain unless the engine
has ingested water. Some engine oil will be lost if
crankcase drain is opened.
 If recoil handle seal has been damaged, the handle
shopuld be replaced.

2.25
MAINTENANCE

ENGINE OIL LEVEL

The oil tank is located on the left side of the vehicle. To
check the oil level:
1. Set machine on a level surface.
2. Start and run engine for 20-30 seconds. This will return
oil to its true level in the oil tank. About a cup of oil will
remain in the crankcase.
3. Stop engine, remove dipstick and wipe dry with a clean
cloth.
4. Reinstall dipstick, screwing into place. Dipstick

NOTE: The dipstick must be screwed completely in to en-

sure accurate measurement.

5. Remove dipstick and check to see that the oil level is in

the normal range. Add oil as indicated by the level on
the dipstick. Do not overfill.
ADD 8 OZ. NORMAL FULL

NOTE: Rising oil level between checks in cool weather Maintain Oil Level In Normal Range
driving, can indicate moisture collecting in the oil reservoir.
If the oil level is over the full mark, change the oil. Screw in completely to check

OIL AND FILTER CHANGE

1. Place vehicle on a level surface.
Recommended Engine Oil:
2. Run engine two to three minutes until warm. Stop
engine. Polaris Premium 4 All Season
3. Clean area around drain plug (B) at bottom of oil tank. Synthetic, 0W/40, PN 2871281
4. Place a drain pan beneath oil tank and remove drain
Ambient Temperature Range:
plug. CAUTION: Oil may be hot. Do not allow hot oil to -40° F to 120° F
come into contact with skin as serious burns may result.
5. Allow oil to drain completely.
6. Replace sealing washer (A) on drain plug. NOTE: The
sealing surfaces on drain plug and oil tank should be
clean and free of burrs, nicks or scratches. E
7. Reinstall drain plug and torque to 14 ft. lbs. (1.9 kgm). C
8. Loosen clamp (E) or bolt (D).
9. Remove oil hose from screen fitting (C) on bottom of
OR
oil tank.
10. Remove screen fitting (C). D

11. Clean screen thoroughly. A

12. Apply Loctite PST 505 or an equivalent pipe B
C
thread sealant or PTFE sealant tape to clean, oil
free threads of fitting.
13. Install fitting and torque to 14-17 ft./lbs..
14. Install oil hose on fitting and tighten clamp to 25
inch/lbs.

2.26
 MAINTENANCE

OIL AND FILTER CHANGE, CONT.

15. Place shop towels beneath oil filter. Using an oil
filter wrench, turn filter counterclockwise to remove.
16. Using a clean dry cloth, clean filter sealing surface
on crankcase.
17. Lubricate O-ring on new filter with a film of engine
oil. Check to make sure the O-ring is in good
condition.
18. Install new filter and turn by hand until filter gasket
contacts the sealing surface, then turn and
additional 1/2 turn.
19. Approximately 1 cup of engine oil will remain in the
crankcase. To drain, remove drain plug found on Filter
lower right side of crankcase.
NOTE: The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or
scratches.
20. Reinstall drain plug.
21. Remove dipstick and fill tank with 2 quarts (1.9 l) of Crankcase Drain
Polaris Premium 4 synthetic oil.
22. Place gear selector in neutral and set parking brake.
23. Prime oil pump using procedure below. Stop
the engine and inspect for leaks.
24. Re-check the oil level on the dipstick and add oil as
necessary to bring the level to the upper mark on the
dipstick. Recoil
25. Dispose of used filter and oil properly. Starter

OIL PUMP PRIMING PROCEDURE Engine Sump Drain Plug - Bottom View
NOTE: This priming procedure must be per-
formed whenever the oil hose connection be-
tween the oil tank and pump inlet has been dis-
connected. Oil Tank Drain Plug Torque:
1. Clamp or pinch off vent line approximately 2 from 14 ft. lbs. (19 Nm)
oil tank to avoid the end of oil tank vent fitting, and
the vent line’s pressure relief slit Crankcase Drain Plug Torque:
14 ft. lbs. (19 Nm)
2. Run engine for 45-60 seconds.
3. Remove the vent line clamp. The oil pump will now Oil Filter Torque:
be properly primed and ready for field operation. Turn by hand until filter gasket
contacts sealing surface, then
To Air Box turn an additional 1/2 turn
Approx.
2 Oil Filter Wrench:
Snap On PN YA997 or 2 1/2 inch

Oil Tank Screen Fitting Torque:

14-17 ft. lbs. (19 Nm)

Oil Tank Slit

Pinch Off
Vent Hose

2.27
MAINTENANCE

VALVE CLEARANCE
Inspect and adjust valve clearance while the engine is cold
and the piston positioned at Top Dead Center (TDC) on
compression stroke.

1. Remove the seat.

2. Remove body panels and fuel tank as necessary to

gain access to valve cover.

3. Remove the spark plug high tension lead and remove

the spark plug. CAUTION: Place a clean shop towel
into the spark plug cavity to prevent dirt from entering.

4. Remove rocker cover bolts, cover and gasket.

NOTE: It may be necessary to tap cover lightly with a

soft-faced hammer to loosen it from the cylinder head.

5. Remove timing inspection plug from recoil housing.

CAUTION: Failure to position the crankshaft at TDC on
compression stroke will result in improper valve adjust-
ment.

6. Rotate engine slowly with recoil rope, watching the

intake valve(s) open and close. Sprocket alignment pin facing up
NOTE: At this point watch the camshaft sprocket locating
pin and slowly rotate engine until locating pin is facing up-
ward, directly in line with the crankshaft to camshaft center
line as shown. The camshaft lobes should be pointing
downward.

Crankshaft-to-Camshaft Centerline

7. Verify accurate TDC positioning by observing the “T”

mark aligned with the pointer in the timing inspection
hole. In this position there should be clearance on all
valves.

2.28
 MAINTENANCE

INTAKE VALVE CLEARANCE ADJUSTMENT

1. Insert a .006″ (.15mm) feeler gauge between end of
intake valve stem and clearance adjuster screw.
2. Using a 10 mm wrench and a screwdriver, loosen
adjuster lock nut and turn adjusting screw until there is
a slight drag on the feeler gauge.
3. Hold adjuster screw and tighten adjuster lock nut
securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
6. Repeat this step for the other intake valve.

INTAKE VALVE CLEARANCE

.006″ (.15 mm)

EXHAUST VALVE CLEARANCE ADJUSTMENT

NOTE: The exhaust valves share a common rocker arm,
and must be adjusted using two feeler gauges.

1. Insert .006 feeler gauge(s) between end of exhaust

valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). NOTE: Both
feeler gauges should remain inserted during
adjustment of each valve.

EXHAUST VALVE CLEARANCE

.006″ (.15 mm)

3. When clearance is correct, hold adjuster screw and

tighten locknut securely 2 Feeler Gauges
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.

2.29
MAINTENANCE

STEERING
The steering components should be checked periodically for loose fasteners, worn tie rod ends, and damage.
Also check to make sure all cotter pins are in place. If cotter pins are removed, they must not be re-used. Always
use new cotter pins.
Replace any worn or damaged steering components. Steering should move freely through entire range of travel
without binding. Check routing of all cables, hoses, and wiring to be sure the steering mechanism is not restricted
or limited. NOTE: Whenever steering components are replaced, check front end alignment. Use only genuine
Polaris parts.

WARNING

Due to the critical nature of the procedures outlined in this chapter, Polaris recommends steering component re-
pair and adjustment be performed by an authorized Polaris Dealer. Only a qualified technician should replace
worn or damaged steering parts. Use only genuine Polaris replacement parts.
One of two methods can be used to measure toe alignment. The string method and the chalk method. If adjust-
ment is required, refer to following pages for procedure.

TIE ROD END / STEERING INSPECTION

 To check for play in the tie rod end, grasp the steering
tie rod, pull in all directions feeling for movement.
 Repeat inspection for inner tie rod end (on steering
post).
 Replace any worn steering components. Steering
should move freely through entire range of travel with-
out binding.

 Elevate front end of machine so front wheels are off the

ground. Check for any looseness in front hub / wheel
assembly by grasping the tire firmly at top and bottom
first, and then at front and rear. Try to move the wheel
and hub by pushing inward and pulling outward.

 If abnormal movement is detected, inspect the hub and

wheel assembly to determine the cause (loose wheel
nuts or loose front hub nut).

 Refer to the Body/Steering or Final Drive chapter for

more information.

CAMBER AND CASTER Check for Loose Wheel or Hub

The camber and caster are non-adjustable.

2.30
 MAINTENANCE

METHOD 1: STRAIGHTEDGE OR STRING

Be sure to keep handlebars centered. See note below.

NOTE: String
should just touch
side surface of rear
tire on each side of
machine.

Measure from string

to rim at front and
rear of rim.
Rear rim measure-
ment should be
1/16″ to 1/8″ (.2 to
.3 cm) more than
front rim measure-
ment.

NOTE: The steering post arm (frog) can be used as an indicator of whether the handle-
bars are straight. The frog should always point straight back from the steering post.

2.31
MAINTENANCE

METHOD 2 CHALK
1. Place machine on a smooth level surface.
2. Set handlebars in a straight ahead position and
secure handlebars in this position. NOTE: The
steering frog can be used as an indicator of whether
the handlebars are straight. The frog should always
point straight back from the steering post.
3. Place a chalk mark on the face of the front tires
approximately 10″ (25.4 cm) from the floor as close to
the hub/axle center line as possible. NOTE: It is
important that both marks be equally positioned from
the ground in order to get an accurate measurement.
Chalk Line
4. Measure the distance between the marks and record Measurement
the measurement. Call this measurement “A”. “A” Measurement “B”

5. Rotate the tires 180° by moving vehicle forward or backward. Position chalk marks facing rearward, even with
the hub/axle centerline.
6. Again measure the distance between the marks and record. Call this measurement “B”. Subtract
measurement “B” from measurement “A”. The difference between measurements “A” and “B” is the vehicle
toe alignment. The recommended vehicle toe tolerance is 1/8″ to 1/4″ (.3 to .6 cm) toe out. This means the
measurement at the front of the tire (A) is 1/8″ to 1/4″ (.3 to .6 cm) wider than the measurement at the rear (B).

TOE ALIGNMENT ADJUSTMENT

7. If toe alignment is incorrect, measure the distance between vehicle center and each wheel. This will tell you
which tie rod needs adjusting. NOTE: Be sure handlebars are straight ahead before determining which tie
rod(s) need adjustment.
CAUTION: During tie rod adjustment it is very important that the following precautions be taken when tightening
tie rod end jam nuts. If the rod end is positioned incorrectly it will not pivot, and may break.
To adjust toe alignment:
 Hold tie rod end to keep it from rotating.
Hold
 Loosen jam nuts at both end of the tie rod. Rod End

 Shorten or lengthen the tie rod until alignment is as re-

quired to achieve the proper toe setting as specified
in Method 1 (1/16″to 1/8″) or Method 2 (1/8″to 1/4″).
 IMPORTANT: When the tie rod end jam nuts are
tightened, be sure to hold tie rod ends so they are par-
allel with the steering arm or the steering frog, respec- Correctly Incorrectly
tively, to prevent rod end damage. Tightened Tightened
Jam Nut Jam Nut
8. After alignment is complete, torque jam nuts to 12-14 ft.
lbs. (1.66-1.93 kg-m).

2.32
 MAINTENANCE

FRONT HUB FLUID LEVEL INSPECTION

To check front hub fluid:
1. Place vehicle on a level surface.
2. Turn wheel until front hub fill/check plug is in either the
4:00 or 8:00 position.
3. Remove fill/check plug.
4. Add Polaris Demand Drive Hub Fluid if necessary until
fluid trickles out. NOTE: Do not force the fluid into the
hub under pressure or seal damage may occur.
5. Reinstall plug.
6. Repeat procedure for other hub.

FRONT HUB FLUID CHANGE

1. Place a drain pan beneath the hub.
2. Remove (3) screws and hub cap. Pry equally in
notches provided until cap is removed.
3. Allow fluid to drain completely.
4. Inspect hub cap O-rings for nicks, cuts or abrasions.
Replace if necessary.
5. Remove check/fill plug.
6. Reinstall the hub cap. NOTE: The check/fill plug
must be removed before reinstalling the hub cap.
7. Turn wheel until front hub fill/check plug is in either the
4:00 or 8:00 position.
8. Add Polaris Demand Drive Hub Fluid until fluid trickles
out. NOTE: Do not force the fluid into the hub under
pressure or seal damage may occur.

Polaris Demand Drive Hub Fluid:

PN 2871654 - 8 oz..
PN 2872277 - 2.5 gallon

2.33
MAINTENANCE

EXHAUST PIPE
The exhaust pipe must be periodically purged of accumu-
lated carbon as follows:
1. Remove the clean out plugs located on the bottom of the
muffler as shown at right.
2. Place the transmission in neutral and start the engine.
Purge accumulated carbon from the system by momen- Clean Out Plug
tarily revving the engine several times.
3. If some carbon is expelled, cover the exhaust outlet and
rap on the pipe around the clean out plugs while revving
the engine several more times.
4. If particles are still suspected to be in the muffler, back
the machine onto an incline so the rear of the machine
is one foot higher than the front. Set the parking brake
and block the wheels. Make sure the machine is in neu-
tral and repeat steps 2 and 3. WARNING: SEE
BELOW.
5. If particles are still suspected to be in the muffler, drive
the machine onto the incline so the front of the machine
is one foot higher than the rear. Set the parking brake
and block the wheels. Make sure the machine is in neu-
tral and repeat steps 2 and 3. WARNING: SEE
BELOW.
6. Repeat steps 2 through 5 until no more particles are ex-
pelled when the engine is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.

WARNING
 Do not perform this operation immediately after the engine has
been run because the exhaust system becomes very hot.
 Because of the increased fire hazard, make sure that there are
no combustible materials in the area when purging the spark
arrestor.
 Wear eye protection.
 Do not stand behind or in front of the vehicle while purging the
carbon from the spark arrestor.
 Never run the engine in an enclosed area. The exhaust con-
tains poisonous carbon monoxide gas.
 Do not go under the machine while it is inclined.
Failure to heed these warnings could result in serious personal injury
or death.

2.34
 MAINTENANCE

BRAKE SYSTEM INSPECTION

The following checks are recommended to keep the brake system in good operating condition. Service life of
brake system components depends on operating conditions. Inspect brakes in accordance with the maintenance
schedule and before each ride.

 Keep fluid level in the master cylinder reservoirs be-

tween “Min” & “Max” lines at all times.
Maximum
 Use Polaris DOT 3 brake fluid (PN 2870990).
 Check brake system for fluid leaks. Minimum
 Check brake for excessive travel or spongy feel.
 Check friction pads for wear, damage and looseness.
 Check surface condition of the disc.
 Inspect thickness of brake pad friction material.
Parking Brake Lock

BRAKE PAD INSPECTION

 Pads should be changed when friction material is worn
to 3/64″ (.1 cm), or about the thickness of a dime.

HOSE/FITTING INSPECTION
Check brake system hoses and fittings for cracks, deterio-
ration, abrasion, and leaks. Tighten any loose fittings and
replace any worn or damaged parts. 3/64″
(.1cm)
Minimum
Thickness

2.35
MAINTENANCE

CENTER DRIVE CHAIN INSPECTION/ADJUSTMENT

1. Remove center chain guard attaching hardware. Press brake pedal downward and remove guard.

2. Loosen center chain eccentric clamp bolts (A).

3. Rotate vehicle forward or rearward until one of sprocket holes aligns with hole provided in eccentric.

4. Insert a large punch or screwdriver through sprocket and into eccentric hole. Rotate vehicle rearward to tight-
en chain. Chain deflection should be 1/4-1/2″ (6-13 mm) with 18 lbs. (8.18 kg) of force at center of chain.

5. Tighten eccentric clamp bolts to 45 ft. lbs. (62 Nm). NOTE: This does not include nut rolling torque. Check
chain tension. CAUTION: Do not over torque or eccentric bearing damage may occur. Check deflection and
adjust again if needed.

Center Drive Chain Adjustment:

1/4-1/2″ (6-13 mm) with 18 lbs. load (8.18 kg)

A
1/4″-1/2″ (6-13 mm)
with 18 lbs load.

Front

Center
Pin Punch 45 ft. lbs.
(62Nm)

2.36
 MAINTENANCE

DRIVE CHAIN INSPECTION/ADJUSTMENT

CAUTION:

Never adjust or operate the vehicle with the rear drive chain slack out of the specified range, as severe damage
to the transmission and drive components can result.

CHAIN INSPECTION
Check the amount of chain slack by moving the vehicle slightly forward to gain slack at the top side of the chain.
Then pull up and down on the chain. Total slack should be as specified below. If slack is not within specification,
adjust the chain.

MIDDLE AXLE CHAIN ADJUSTMENT

1. Loosen chain guard.
2. Loosen two eccentric locking bolts.
3. Insert a pin punch through the sprocket hub and into the eccen-
tric axle housing. Drive Chain Adjustment
4. Roll the vehicle ahead or back to adjust chain slack to the proper 3
dimension. Correct chain slack adjustment is 1 1/4″ to 1 1/2″
(30-38 mm) total at the midpoint.
5. Roll the vehicle ahead and check tension in several places
around the chain.
6. Tighten the eccentric locking bolts to 60 ft. lbs. 2
7. Reinstall chain guard.

NOTE: Reposition chain guide to allow 1/8″ (.3 cm) clearance be-
tween sprocket and guide.

REAR AXLE DRIVE CHAIN ADJUSTMENT

To adjust the rear axle drive chain on 6x6 models, loosen the rear most eccentric and rotate using the same meth-
od as outlined for the middle axle chain. Total slack, however, should be adjusted to 1/4″-1/2″ (6-13 mm).

Chain Deflection
Middle Axle:
1 1/4″ to 1 1/2″
Middle Axle:
(30-38 mm)
1 1/4- 1 1/2″(30- 38 mm)
Rear Axle:
1/4-1/2″(6-13 mm)

Rear Axle:
1/4″-1/2″ (6-13 mm)

2.37
MAINTENANCE

SUSPENSION SPRING PRELOAD ADJUSTMENT

Operator weight and vehicle loading affect suspension
spring preload requirements. Adjust as necessary.

Center Spring
FRONT SUSPENSION Adjustment Ring

Compress and release front suspension. Damping should

be smooth throughout the range of travel.

Check all front suspension components for wear or dam-

age.

Inspect front strut cartridges for leakage.

CENTER/REAR SUSPENSION
Compress and release rear suspension. Damping should
be smooth throughout the range of travel.

Check all rear suspension components for wear or dam-

age.

Inspect shock for leakage.

Shock Spanner Wrench

PN 2870872

CONTROLS

ÁÁÁÁÁ
Check controls for proper operation, positioning and

ÁÁÁÁÁ
adjustment. Spacer Tab
Brake control and switch must be positioned to allow brake
lever to travel throughout entire range without contacting
switch body.

2.38
 MAINTENANCE

WHEELS
Inspect all wheels for runout or damage. Check wheel nuts
and ensure they are tight. Do not over tighten the wheel
nuts.

WHEEL, HUB, AND SPINDLE TORQUE TABLE

Item Specification
Front Wheel Nuts 20 Ft. Lbs.
Rear Wheel Nuts 50 Ft. Lbs.
Front Spindle Nut Refer to procedure listed in Chapter 7
Rear Hub Retaining Nut 80 Ft. Lbs.

WHEEL REMOVAL FRONT OR REAR

1. Stop the engine, place the transmission in gear
and lock the parking brake.
2. Loosen the wheel nuts slightly.
3. Elevate the side of the vehicle by placing a
suitable stand under the footrest frame.
4. Remove the wheel nuts and remove the wheel.

WHEEL INSTALLATION
Tapered nuts - install with
1. With the transmission in gear and the parking brake tapered side against wheel
locked, place the wheel in the correct position on the
wheel hub. Be sure the valve stem is toward the
outside and rotation arrows on the tire point toward
forward rotation.
2. Attach the wheel nuts and finger tighten them.
3. Lower the vehicle to the ground.
4. Securely tighten the wheel nuts to the proper torque
listed in the table above.

CAUTION:

If wheels are improperly installed it could affect vehicle

handling and tire wear. On vehicles with tapered rear
wheel nuts, make sure tapered end of nut goes into taper
on wheel.

2.39
MAINTENANCE

TIRE PRESSURE
Tire Pressure Inspection (PSI - Cold)
Front Center Rear
5 5 5

TIRE INSPECTION

CAUTION:

 Maintain proper tire pressure. Refer to the warning tire

pressure decal applied to the vehicle.

 Improper tire inflation may affect ATV maneuverability. Tread

Depth 1/8 (3 mm)
 When replacing a tire always use original equipment
size and type.

 The use of non-standard size or type tires may affect

ATV handling.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (3
mm) or less.

WARNING
Operating an ATV with worn tires will increase the possibility of
the vehicle skidding easily with possible loss of control.
Worn tires can cause an accident.
Always replace tires when the tread depth measures 1/8″ (.3 cm)
or less.

FRAME, NUTS, BOLTS, FASTENERS

Periodically inspect the tightness of all fasteners in accor-
dance with the maintenance schedule. Check that all cot-
ter pins are in place. Refer to specific fastener torques
listed in each chapter.

2.40