Polaris PTV 4x4 Series 10 User manual

WARNING
The engine exhaust from this
product contains chemicals known
to cause cancer, birth defects or
other reproductive harm.

1

2
All information in this manual is based on the latest product data and specifications
available at the time of printing. Polaris Industries Inc. reserves the right to make
product changes and improvements that may affect illustrations or explanations.
No part of this manual shall be reproduced or used without the written permission of
Polaris Industries Inc.
Copyright 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

3
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.
Polaris Recreational and Utility Vehicles
SSnowmobiles
SAll-terrain vehicles (ATVs)
SPersonal watercraft
SVictory motorcycles
SRANGER utility vehicles
Polaris Professional Series Workmobilest
SUtility Task Vehiclest(UTVs)
SPersonal Task Vehiclest(PTVs)
SAll-Surface Loaders (ASLs)
We believe Polaris sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your Polaris vehicle, making it the finest vehicle we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your
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.
Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
We also take great pride in our Parts Apparel and Accessories (PAA)
products, available through our online store at www.purepolaris.com.
Have your accessories and clothing delivered right to your door!
Polaris, Polaris The Way Out, and Workmobiles are registered
trademarks of Polaris Industries Inc.

4
IDENTIFICATION NUMBERS
The frame vehicle identification number (VIN) (1) and engine serial
number (2) are important for model identification when registering
your vehicle, when obtaining insurance, and when ordering
replacement parts. If your vehicle is stolen, these numbers are essential
to its recovery and identification.
Remove the spare key and store it in a safe place. Your key can be
duplicated only by mating a Polaris key blank with one of your
existing keys. If both keys are lost, the ignition switch must be
replaced. See your Polaris dealer.
NOTE: Record your vehicle’s ID numbers and key number (3) in the
spaces provided.
2
131XX
3
Frame VIN:
Engine Serial Number:
Vehicle Model Number:
Key Number:

5
TABLE OF CONTENTS
WELCOME 3........................................
IDENTIFICATION NUMBERS 4........................
TABLE OF CONTENTS 5.............................
SAFETY 6..........................................
CONTROLS 38......................................
FEATURES 48.......................................
OPERATION 51.....................................
NOISE EMISSION CONTROL
SYSTEM REGULATION 69...........................
MAINTENANCE AND LUBRICATION 70................
SPECIFICATIONS 112................................
POLARIS RECOMMENDED PRODUCTS 115...........
TROUBLESHOOTING 116............................
WARRANTY 120.....................................
INDEX 123..........................................
NOTE: Illustrations used in this manual are for general representation
only. Your model may differ.

6
SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Know Your Vehicle
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment.
Read and understand your owner’s manual, which includes valuable
information about all aspects of your vehicle, including safe operating
procedures.
The PTV is an off-road vehicle. Familiarize yourself with all laws and
regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended
maintenance program outlined in your owner’s manual. This
preventive maintenance program is designed to ensure that all critical
components on your vehicle are thoroughly inspected at specific
intervals.
Safety Training
When you purchased your new PTV, your dealer offered a hands-on
safety training course that covers all aspects of vehicle safety. You
were also provided with printed materials that explain safe operating
procedures. You should review this information on a regular basis.
If you purchased a used Polaris PTV from a party other than a Polaris
dealer, you can request this free safety training from any authorized
Polaris dealer.
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris PTV is not a toy and can be hazardous to operate. This
vehicle handles differently than other vehicles, such as
motorcycles and cars. A collision or rollover can occur quickly,
even during routine maneuvers like turning, or driving on hills or
over obstacles, if you fail to take proper precautions.
Read and understand your owner’s manual and all warnings
before operating a Polaris PTV.

7
SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your vehicle. 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.
The safety alert warning indicates a potential hazard that may result
in serious injury or death.
The safety alert caution indicates a potential hazard that may result
in minor personal injury or damage to the vehicle.
CAUTION
NOTE:
Anote will alert you to important information or instructions.
Acaution indicates a situation that may result in damage to the
vehicle.
CAUTION
WARNING

8
SAFETY
Operator Safety
SRead this manual and all labels carefully, and follow the operating
procedures described.
SNever operate the PTV without proper instruction. Take a training
course. Beginners should receive training from a certified instructor.
Contact an authorized Polaris dealer or call Polaris at
1-800-342-3764 to find out about the training courses nearest you.
SNever allow anyone under 16 years of age to operate this vehicle.
SNever permit a guest to operate the vehicle unless the guest has read
this manual and all product labels and has completed a certified safe-
ty training course.
SAlways avoid operating this vehicle on paved surfaces, including
sidewalks, driveways, parking lots, and streets.
SNever operate this vehicle on a public street, road or highway, in-
cluding a dirt or gravel road.
SNever operate this vehicle without wearing an approved helmet that
fits properly. Always wear eye protection (goggles or face shield),
gloves, boots, a long-sleeved shirt or jacket, and long pants.
SNever consume alcohol or drugs before or while operating this ve-
hicle.
SNever operate at excessive speeds. Travel at speeds appropriate for
the terrain, visibility and operating conditions, and your experience.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your vehicle before each use to make sure it’s in safe
operating condition. Always follow the inspection and maintenance
procedures and schedules outlined in your owner’s manual.
SAlways keep both hands on the handlebars and both feet on the foot-
rests of the vehicle during operation.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain conditions.
SNever operate on excessively rough, slippery, or loose terrain.
WARNING
Serious injury or death can result if you do not follow these
instructions and procedures, which are outlined in further detail
within your owner’s manual.