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

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

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.

Polaris Industries Inc.

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.

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...............................

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...........................

VEHICLE IDENTIFICATION NUMBERS

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

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

Table of contents

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