Polaris UTV 2x4 Series 11 User manual

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

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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.

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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.

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VEHICLE IDENTIFICATION NUMBERS
The vehicle frame vehicle identification number (VIN)(1), engine serial
number and vehicle model number (2) are important for model
identification when registering your vehicle, when obtaining insurance,
and when ordering replacement parts. In the event your vehicle is
stolen, these numbers are essential to the recovery and identification of
your vehicle.
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.
1
31XX
3
2
Frame VIN (behind left front wheel):
Engine Serial Number (right front side of engine crankcase):
Vehicle Model Number (under hood):
Key Number:

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TABLE OF CONTENTS
WELCOME 3.................................
VEHICLE IDENTIFICATION NUMBERS 4........
TABLE OF CONTENTS 5......................
SAFETY 7...................................
FEATURES 25...............................
FEATURES AND CONTROLS 30...............
CONTROLS 31...............................
OPERATION 34..............................
NOISE EMISSION CONTROL SYSTEM 53......
MAINTENANCE AND LUBRICATION 54.........
SPECIFICATIONS 96.........................
POLARIS RECOMMENDED PRODUCTS 98.....
TROUBLESHOOTING 99......................
WARRANTY 102..............................
INDEX 104...................................

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-NOTES-

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SAFETY
Operator Safety
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may
ride as a passenger in this vehicle.
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 Polaris UTV 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.
WARNING
Failure to follow the warnings contained in this manual can result
in severe injury or death.
A Polaris UTV 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 the vehicle.

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SAFETY
Operator Safety
The following signal words and symbols appear throughout this
manual and on your Polaris UTV. 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 Polaris UTV 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
A note will alert you to important information or instructions.
A caution indicates a situation that may result in damage to the
vehicle.
CAUTION
WARNING

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SAFETY
Operator Safety
SRead this manual and all labels carefully. Follow the operating pro-
cedures described.
SNever allow anyone without a valid driver’s license to operate this
vehicle.
SMinimum age recommendation for passengers is five years old. Pas-
sengers under five years of age require special restraints which are
not available with this vehicle. Driver and passenger should wear
their seat belts at all times.
SNever permit a guest to operate this vehicle unless the guest has read
this manual and all product labels.
STo reduce tipover risk, be especially careful when encountering ob-
stacles and slopes and when braking on hills or during turns.
SThis vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.
SHelmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
SNever consume alcohol or drugs before or while operating this ve-
hicle.
SNever operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your experi-
ence.
SNever attempt wheelies, jumps or other stunts.
SAlways inspect your vehicle each time you use it to make sure it’s in
safe operating condition. Always follow the inspection and mainte-
nance procedures and schedules described in this manual.
SAlways keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.
SAlways travel slowly and use extra caution when operating on unfa-
miliar terrain. Be alert to changing terrain.
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.

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SAFETY
Operator Safety
SAlways follow proper procedures for turning as described in this
manual. Practice turning at slow speeds before attempting to turn at
faster speeds. Never turn at excessive speeds.
SAlways have this vehicle checked by an authorized Polaris dealer if
it has been involved in an accident.
SNever operate this vehicle on hills too steep for the vehicle or for
your abilities. Practice on smaller hills before attempting larger hills.
SAlways follow proper procedures for climbing hills as described in
this manual. Check the terrain carefully before attempting to climb a
hill. Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly or make sudden gear changes.
Never go over the top of a hill at high speed.
SAlways follow the proper procedures outlined in this manual for
traveling downhill and for braking on hills. Check the terrain care-
fully before descending a hill. Never travel downhill at high speed.
Avoid going downhill at an angle, which would cause the vehicle to
lean sharply to one side. Travel straight down the hill where pos-
sible.
SAlways check for obstacles before operating in a new area. Never
attempt to operate over large obstacles such as rocks or fallen trees.
Always follow the proper procedures outlined in this manual when
operating over obstacles.
SAlways be careful of skidding or sliding. On slippery surfaces such
as ice, travel slowly and exercise caution to reduce the chance of
skidding or sliding out of control.
SNever operate your vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced
stopping ability. Test your brakes after leaving water. If necessary,
apply them lightly several times to let friction dry out the pads.
SAlways be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it’s safe to proceed in reverse,
move slowly. Avoid turning at sharp angles in reverse.
SAlways use the proper size and type of tires specified in this manual.
Always maintain proper tire pressure as specified on page 97.

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SAFETY
Operator Safety
SNever modify this vehicle through improper installation or use of
accessories.
SNever exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and
follow the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.
SAlways wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
SAlways keep arms and legs inside the cab frame while the vehicle is
in motion.
SAlways apply the parking brake before getting out of the vehicle.
Seepage33.
SAlways activate the foot pedal brake before releasing the park brake.
SAlways turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks.
Gasoline is extremely flammable. See page 24 for refueling instruc-
tions.
SAlways remove the ignition key when the vehicle is not in use to
prevent unauthorized use or accidental starting.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at
1-800-342-3764.

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SAFETY
Operator Safety
Equipment Modifications
We are concerned for the safety of our customers and for the general
public. Therefore, we strongly recommend that consumers do not
install on a Polaris UTV any equipment that may increase the speed or
power of the vehicle, or make any other modifications to the vehicle
for these purposes. Any modifications to the original equipment of the
vehicle create a substantial safety hazard and increase the risk of bodily
injury.
The warranty on your Polaris UTV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.
NOTE: The addition of certain accessories, including (but not limited
to) mowers, blades, tires, sprayers, or large racks, may change the
handling characteristics of the vehicle. Use only Polaris-approved
accessories, and familiarize yourself with their function and effect on
the vehicle.
WARNING
Make sure your Polaris UTV is in excellent operating condition at
all times. We strongly recommend that the operator check all
safety components before each ride.
Polaris UTVs are designed to provide safe operation when used
as directed. Failure of critical machine components may result
from operation with any modifications, especially those that
increase speed or power. The UTV may become aerodynamically
unstable at speeds higher than those for which it is designed.
Loss of control may occur at higher speeds. Modifications may
also create a safety hazard and lead to bodily injury.
Do not make any modifications to your UTV.

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SAFETY
Operator Safety
POTENTIAL HAZARD
Stalling, rolling backwards while climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when
climbing a hill.
Ifyouloseallforwardspeed:
Apply the brakes.
Lock the parking brake after when
fully stopped.
If you begin rolling backwards:
Never apply engine power.
Apply the brake gradually.
When fully stopped, lock parking brake.
In the event of an accident, have a qualified service dealer check
the complete vehicle for possible damage, including (but not
limited to) brakes, throttle and steering.
WARNING

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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle’s tires are designed for off-road use only, not
for use on pavement. Paved surfaces may seriously affect
handling and control of the vehicle, and may cause the
vehicle to go out of control.
Avoid operating the vehicle on pavement. If you must
operate on a paved surface, travel slowly and do not make
sudden turns or stops.
WARNING
POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the operator does
not know how to operate the vehicle properly in different
situations and on different types of terrain.
All operators must read and understand the Owner’s Manual
and all warning and instruction labels before operating the
vehicle.
WARNING

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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or
highway, including dirt or gravel.
In many states it’s illegal to operate vehicles of this type on
public streets, roads and highways.
WARNING
POTENTIAL HAZARD
Operating this vehicle after consuming alcohol or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving a UTV requires your full attention. DO NOT drink
alcohol or use drugs or medications before or while driving.
They will reduce your alertness and slow your reaction
time. In most states and provinces, it’s prohibited by law to
drive while intoxicated or under the influence of drugs.
WARNING

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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and
operating conditions, and your experience.
WARNING
POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.
WARNING
POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the UTV and/or the operator
fall through the ice.
HOW TO AVOID THE HAZARD
Never operate the UTV on a frozen body of water.
WARNING

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SAFETY
Operator Safety
POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your UTV before each use to make sure it’s in safe
operating condition.
Always follow the inspection and maintenance procedures and
schedules described in the Owner’s Manual.
POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on
unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar
terrain.
Always be alert to changing terrain conditions when operating the
vehicle. You may come upon hidden rocks, bumps, or holes
suddenly, without enough time to react.
WARNING
WARNING

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SAFETY
Operator Safety
POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or
uneven tire pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified in the Owner’s
Manual for this vehicle. See page 97.
Always maintain proper tire pressure as described on the decal
and in the Owner’s Manual. See page 97.
WARNING
POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this
vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver’s license should operate a Polaris
UTV.
Even though a child may be within the age group for which some
vehicles are recommended, he or she may not have the skills,
abilities, or judgment needed to operate the vehicle safely and
may be involved in a serious accident.
WARNING