Polaris UTV Series 10 2x4 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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WELCOME
Thank you for purchasing a Polaris vehicle, 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 vehicles
manufactured in the world today. Many years of experience in
engineering, design, and development have gone into making your
UTV 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, but major repairs are
covered in the Polaris Service Manual and should be performed by a
Factory Certified Master Service Dealer (MSD) Technician.
Your Polaris UTV 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 in our online store at
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 2002
Polaris Industries Inc.
All Rights Reserved Printed in the U.S.A.

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THIS VEHICLE IS NOT A TOY AND CAN BE
HAZARDOUS TO OPERATE. This vehicle handles differently
from other vehicles, including motorcycles and cars. A collision or
rollover can occur quickly, even during routine maneuvers such as
turning and driving on hills or over obstacles if you fail to take proper
precautions.
SEVERE INJURY OR DEATH can result if you do not follow
these instructions:
nRead this manual and all labels carefully. Follow the operating
procedures described.
nNever allow anyone without a valid driver’s license to operate this
vehicle.
nMinimum age recommendation for passengers is five years old.
Passengers 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.
nNever permit a guest to operate this vehicle unless the guest has
read this manual and all product labels.
nTo reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.
nAlways fasten your seat belts securely around you.
nThis vehicle is for off road use only. Never operate on public
roads. Always avoid paved surfaces.
nHelmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.
nNever consume alcohol or drugs before or while operating this
vehicle.
nNever operate at excessive speeds. Always travel at a speed proper
for the terrain, visibility and operating conditions, and your
experience.
nNever attempt wheelies, jumps or other stunts.
nAlways inspect your vehicle each time you use it to make sure it’s
in safe operating condition. Always follow the inspection and
maintenance procedures and schedules described in this manual.
nAlways keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.

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nAlways travel slowly and use extra caution when operating on
unfamiliar terrain. Be alert to changing terrain.
nNever operate on excessively rough, slippery or loose terrain.
nAlways 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.
nAlways have this vehicle checked by an authorized Polaris dealer if
it has been involved in an accident.
nNever operate this vehicle on hills too steep for the vehicle or for
your abilities. Practice on smaller hills before attempting larger
hills.
nAlways 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.
nAlways follow the proper procedures outlined in this manual for
traveling downhill and for braking on hills. Check the terrain
carefully 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 possible.
nAlways follow proper procedures for crossing the side of a hill as
described in this manual. Avoid hills with excessively slippery or
loose surfaces. Never attempt to turn the vehicle around on any
hill until you have mastered (on level ground) the turning
technique described in this manual. Avoid crossing the side of a
steep hill if possible.
nAlways 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.
nAlways 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.

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nNever 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.
nAlways 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.
nAlways use the proper size and type of tires specified in this
manual. Always maintain proper tire pressure as specified on page
97.
nNever modify this vehicle through improper installation or use of
accessories.
nNever 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.
nAlways wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.
nAlways keep arms and legs inside the cab frame while the vehicle
is in motion.
nAlways apply the parking brake before getting out of the vehicle.
Seepage46.
nAlways activate the foot pedal brake before releasing the park
brake.
nAlways 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 54 for
refueling instructions.
FOR MORE INFORMATION ABOUT SAFETY, call Polaris at
1-800-342-3764.

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Additional Important Information
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
UTV substantially increase the risk of bodily injury. Modifications
may create a substantial safety hazard.
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.
We also advise you to strictly follow the recommended maintenance
program outlined in this manual. This preventive maintenance
program is designed to ensure that all critical components on the
vehicle are thoroughly inspected by your dealer at various mileage
intervals.
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.
Be sure any accessories added to this vehicle have been approved by
Polaris, and familiarize yourself with their function and effect on the
vehicle.

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TABLE OF CONTENTS
Vehicle Identification Numbers 11.............
Safety 12....................................
Features and Controls 36.....................
Operation 47.................................
Noise Emission 55...........................
Maintenance and Lubrication 56...............
Specifications 96.............................
Troubleshooting 98..........................
Warranty 100................................

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VEHICLE IDENTIFICATION NUMBERS
Important: Record your vehicle’s identification numbers in the
spaces provided.
Frame VIN:
Engine Serial Number (right front side of engine crankcase)
NOTE: Remove the spare key and store in a safe place.
The vehicle frame vehicle identifaction number (VIN) and engine
serial number 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.
Vehicle Model Number:
Dealer Imprint
VIN

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

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SAFETY
Operator Safety
WARNING
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.
Make sure your 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. DO NOT MODIFY YOUR MACHINE.
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.
The warranty on your entire machine is terminated if any
equipment has been added, or any modifications have been
made, to increase the speed or power of the 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 machine 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 on 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
Never consume alcohol or drugs before or while driving this
vehicle.
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
Safe operation of this vehicle requires good judgement and
physical skills. Persons with cognitive or physical disabilities who
operate this vehicle have an increased risk of overturns and loss
of control, which could result in serious injury or death.
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