Polaris ATV 2002 User manual

WARNING
The engine exhaust from this
product contains chemicals
known to cause cancer, birth de-
fects or other reproductive harm.
A card containing important safey information should be attached
to the owner’s manual on the next page. If you cannot locate this
card, or if it has been removed, please call 1-800-342-3764 for as-
sistance.

Indicates a potential hazard that could result in serious
injury or death.
WARNING

1
We’ve created a web site, just for YOU!
STechnical tips
SNew product introductions
SEvent schedules
SParts and Service Manual information
SExciting details about The Way Out
Check it out...
www.polarisindustries.com/owner

2
WELCOME
Thank you for choosing Polaris, and welcome to our world-wide
family of Polaris enthusiasts. Polaris proudly produces an exciting line
of recreational products, including snowmobiles, all-terrain vehicles,
personal watercraft, utility vehicles, and Victory motorcycles.
We believe Polaris sets the standard of excellence for all recreational
vehicles manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
Polaris vehicle the finest machine we’ve ever produced.
Follow the instructions and recommendations in this Owner’s Manual
for safe and enjoyable operation of your vehicle. Your Owner’s Manual
contains instructions for minor maintenance. Major repairs are covered
in the Polaris Service Manual and should be performed by a Factory
Certified MSD (Master Service Dealer) Technician.
Your Polaris dealer knows your vehicle best and is interested in your
complete satisfaction. Return to your dealership for all of your service
needs during, and after, the warranty period.
Polaris also takes great pride in our PAA (Parts Apparel and
Accessories) which are available on our online store
www.purepolaris.com. Have your accessories and clothing delivered
right to your door!
Polaris and Polaris The Way Out are registered trademarks of Polaris
Industries Inc.
Copyright 2001
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

3
ATTENTION!
This is an ADULT VEHICLE ONLY; not a toy. Operation is
prohibited for anyone under 16 years of age. READ AND
UNDERSTAND WARNINGS AND OWNER’S MANUAL BEFORE
OPERATION.
KNOW YOUR VEHICLE BEFORE YOU BEGIN RIDING!
Read this manual thoroughly referring to the various areas which are
being discussed on your machine. Operating this vehicle carries with it
responsibilities for your personal safety, the safety of others, and the
protection of our environment.
SAFETY TRAINING
When you purchased this vehicle your dealer offered a hands-on safety
training course covering all aspects of ATV safety. In addition, you
were provided with certain printed material which instructs you on safe
operating procedures.
You should review this information on a regular basis. In the event
you purchased a used Polaris ATV from a party other than a Polaris
dealer, you can obtain this safety training at no charge from any
authorized Polaris dealer.
Failure to follow the warnings contained in this manual can result in
SEVERE INJURY OR DEATH.
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

4
TABLE OF CONTENTS
Vehicle Identification Numbers 6..............
Safety 7 - 42.................................
Understanding Warnings 7.........................
Key Safety Issues 8...............................
Decals and Locations 12...........................
Operator Safety 22................................
Features and Controls 43 - 65.................
Controls 43.......................................
Features 58......................................
Operation 66 - 70.............................
Pre Ride Inspection 66............................
Vehicle Break-In Period 67.........................
Starting the Engine 70.............................
Carrying Loads 72................................
Noise Emission Control System 75............
Riding 76 - 87................................
Pre Ride Inspection 76............................
Safe Riding Tips 77...............................

5
TABLE OF CONTENTS
Maintenance and Lubrication 88 - 168..........
Periodic Maintenance Schedule 88..................
Lubrication Recommendations 94...................
Maintenance Record 100..........................
Cooling System 101...............................
Lubrication 104...................................
Filter Systems 127................................
Adjustments 130..................................
Lights 146........................................
Spark Plugs 153..................................
Water Service 154................................
Spark Arrestor 155................................
Recoil Housing 157................................
PVT 158.........................................
Battery 161.......................................
Side Panel Removal 164...........................
Cleaning and Storage 165..........................
Trouble Shooting 169 - 172....................
Warranty 173 - 175...........................

6
VEHICLE IDENTIFICATION NUMBERS
2
1
Record these numbers from your ATV in the spaces provided.
1. Frame VIN (found on the lower left side of the frame tube)
2. Engine Serial Number (Right front side of engine crankcase)
Remove the spare key and store in a safe place. Your key can be
duplicated only by obtaining a key blank from Polaris and having it
cut by mating it with your existing key.
The vehicle frame and engine serial numbers are important for model
identification when registering your vehicle, obtaining insurance or
whenever replacement parts are required. In the event your vehicle
were stolen these numbers are essential to the recovery and
identification of your ATV.
Dealer Imprint

7
SAFETY
Understanding Warnings
The following two pages identify signal words and symbols that appear
in this manual. Your safety is involved when these words and symbols
are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol, on your vehicle or in this manual,
alerts you to the potential for personal injury.
Indicates a potential hazard that could result in serious injury or
death.
Indicates a potential hazard that may result in minor personal
injury or damage to the machine.
WARNING
CAUTION
NOTE
“NOTE:” will alert you to important information or instructions.
Indicates a situation that may result in damage to the machine.
CAUTION