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Polaris ATV 2002 User Manual

Polaris ATV 2002
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161
MAINTENANCE AND LUBRICATION
Battery
Replenishing the Battery Fluid
A poorly maintained battery will
deteriorate rapidly. Check the
battery fluid level often. The fluid
level should be kept between the
upper and lower l evel marks.
To refill use only distilled water.
Tap water contains minerals which
are harmful to a battery.
Whenever removing the battery, disconnect the negative (black)
cable first. When reinstalling the battery, connect the negative
(black) cable last or an explosive situation could result causing
serious injury or death.
WARNING
Battery electrolyte is poisonous. It contains sulfuric acid. Serious
burns can result from contact with skin, eyes or clothing.
Antidote:
External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk
of magnesia, beaten egg, or vegetable oil. Call physician
immediately.
Eyes: Flush with water for 15 minutes and get prompt medical
attention.
Batteries produce explosive gases. Keep sparks, flame,
cigarettes, etc. away. Ventilate when charging or using in an
enclosed space. Always shield eyes when working near batteries.
KEEP OUT OF REACH OF CHILDREN.
WARNING
Maintain
between
upper and
lower level
marks

Table of Contents

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Polaris ATV 2002 Specifications

General IconGeneral
BrandPolaris
ModelATV 2002
CategoryOffroad Vehicle
LanguageEnglish

Summary

Welcome to Polaris

Polaris Brand Information

Information about Polaris's commitment to excellence in recreational vehicles.

Parts, Apparel, and Accessories

Details on how to purchase Polaris parts, apparel, and accessories online.

Important Attention Notices

Adult Vehicle Use Only

Warning that the vehicle is for adult use only and operation by minors is prohibited.

Safety Training Importance

Importance of completing a safety training course for proper ATV operation.

Vehicle Identification

Frame VIN Location

Location of the Frame VIN on the ATV for identification purposes.

Engine Serial Number Location

Location of the Engine Serial Number on the ATV for identification purposes.

Understanding Safety Warnings

Safety Alert Symbol Meaning

Identifies the safety alert symbol and its purpose for personal injury warnings.

Hazard Warning Definitions

Explains meanings of WARNING, CAUTION, and NOTE signal words in the manual.

Key Safety Considerations

Protect Your Sport

Guidelines for responsible riding to maintain the sport's integrity and respect.

ATV Hazard Awareness

Highlights that ATVs are not toys and can be hazardous to operate.

Critical Safety Instructions

Proper Instruction and Training

Stresses the importance of proper instruction and training before operating the ATV.

Age and Guest Operation Rules

Prohibits operation by those under 16 and requires guest training.

Safe Riding Environment

Advises avoiding paved surfaces and public roads for ATV operation.

Protective Gear Requirements

Mandates wearing approved helmets, eye protection, gloves, boots, and protective clothing.

Substance Abuse Prohibition

Prohibits alcohol or drug consumption before or during ATV operation.

Speed and Stunt Limitations

Advises against excessive speeds and stunts like wheelies.

Vehicle Inspection and Control

Emphasizes pre-ride inspection and maintaining control with both hands and feet.

Terrain and Weather Caution

Advises caution on unfamiliar terrain, slippery surfaces, and in changing conditions.

Turning and Water Operation

Provides guidance on proper turning techniques and caution when operating through water.

Safety Decals and Locations

Warning Decal Overview

Describes warning decals placed on the vehicle for rider protection and instructions.

General ATV Safety Warnings

Covers critical warnings like no public roads, no passengers, no alcohol/drugs, and proper training.

Handlebar and Control Decals

Shows locations of decals related to handlebar controls and operational warnings.

Age and Hill Operation Warnings

Advises on safe hill operation, reverse use, and parking brake precautions.

Operator Safety Guidelines

Safe Riding Gear Recommendations

Outlines essential protective gear including helmet, eye protection, gloves, boots, and clothing.

Importance of Proper Instruction

Emphasizes that operating without proper instruction greatly increases accident risk.

Age Recommendations for ATV Use

Warns that failure to follow age recommendations can lead to severe injury or death.

Passenger Carrying Prohibition

States that carrying a passenger is prohibited as it affects balance and control.

Paved Surface Operation Warning

Warns that ATVs are for off-road use; paved surfaces affect handling and control.

Public Road Operation Prohibition

Prohibits operating the ATV on public streets, roads, or highways due to collision risks.

Helmet and Protective Gear Use

Stresses wearing approved helmets, eye protection, and proper clothing to prevent severe injury.

Alcohol and Drug Prohibition

Prohibits alcohol or drug use as it impairs judgment, reaction, and balance.

Excessive Speed Warning

Warns that excessive speeds increase the risk of losing control and causing accidents.

Stunt Riding Prohibition

Discourages stunts like wheelies and jumps due to increased accident and overturn risk.

Pre-Operation Inspection and Maintenance

Emphasizes pre-ride inspection and proper maintenance for accident prevention.

Hand and Foot Placement

Advises keeping both hands on handlebars and feet on footrests during operation for control.

Unfamiliar Terrain Operation

Advises slow speeds and alertness on unfamiliar terrain to avoid hidden obstacles.

Rough/Slippery Terrain Caution

Warns against excessively rough, slippery, or loose terrain without proper skills to avoid loss of control.

Improper Turning Procedures

Warns that improper turning can cause loss of control, collision, or overturn.

Steep Hill Operation Limits

Advises against operating on hills too steep for abilities or exceeding 25 degrees.

Improper Hill Climbing Procedures

Details safe hill climbing, including terrain checks, weight transfer, and avoiding sudden throttle.

Improper Hill Descending Procedures

Guides on safe hill descending, including terrain checks, weight transfer, and speed control.

Improper Hill Crossing/Turning

Warns about risks of crossing or turning on hills and advises mastering techniques on level ground.

Stalling or Rolling Backwards on Hills

Provides procedures for stalling or rolling backwards while climbing a hill to prevent overturn.

Improper Operation Over Obstacles

Advises checking for obstacles and using caution when riding over them to prevent loss of control.

Skidding and Sliding Hazards

Warns that skidding or sliding can cause loss of control and potential overturn.

Deep or Fast Flowing Water Operation

Advises against deep water; if unavoidable, proceed slowly, balance weight, and test brakes after.

Improper Tire and Pressure Warnings

Warns that improper tires or pressure affect handling and increase accident risk.

Improper Modification Warnings

Advises against improper modifications as they can affect handling and lead to accidents.

Post-Accident Inspection Recommendation

Recommends dealer inspection after a rollover for damage to critical components.

Cognitive/Physical Ability Requirements

States safe operation requires good judgment and physical skills; disabilities increase risk.

Ignition Key Security

Warns that leaving keys in ignition can lead to unauthorized use and injury or death.

Controls and Features Overview

Engine Electrical Controls

Describes the override switch, main switch, and engine stop switch functions.

Throttle and Choke Controls

Explains throttle lever operation and choke usage for starting.

Brake Controls

Explains brake operation and pre-ride lever functionality checks.

Front and Rear Brake System

Details brake fluid checks and the Electronic Throttle Control (ETC) system.

Parking Brake Operation

Details setting the parking brake and important safeguards.

Auxiliary Brake System

Explains auxiliary brake operation and fluid level checks.

Engine Fuel and Oil System

Explains fuel system operation and safety precautions for gasoline.

Fuel Handling Safety Guidelines

Lists safety practices for refueling, including ventilation and no smoking.

Two-Cycle Engine Oil System

Specifies using only Polaris injection oil for two-cycle engines.

Transmission Gear Selector

Explains shift patterns, selector lever positions, and low forward gear usage.

Manual Transmission Operation

Details manual shift procedures and the brake start feature.

Shift Pedal Operation

Describes shift pedal functionality and provides a gears shifting procedure.

Shifting to Reverse and Lighting

Explains shifting to reverse and notes the lack of highway lighting.

Shifting From Reverse to Forward

Details procedures for shifting from reverse to forward and for deceleration.

Recoil Starter Operation

Explains using the recoil starter for operation when the battery is weak.

Exclusive AWD System

Describes the Demand 4 Drive (AWD) system activated by a switch for enhanced traction.

Disengaging Wheel Hubs

Provides instructions on disengaging front wheel hubs if they remain engaged after use.

Indicator Lights

Explains the function of various indicator lights like Neutral, Reverse, and Oil Warning.

Electronic Speedometer

Details the speedometer's functions including distance, trip, hours, and reverse speed limit.

Speedometer Sub-menu Access

Explains two methods to access the speedometer's sub-menu for settings and features.

Speedometer Service Reminders

Guides on setting service reminders based on programmed hours or distance.

Auxiliary Power Outlet

Describes auxiliary power outlets for operating accessories like spot lights.

Operation Procedures

Pre-Ride Inspection Checklist

Provides a comprehensive checklist for verifying the machine's working order before each ride.

Break-In Period for 2-Cycle Engines

Outlines essential procedures for the break-in period of new 2-cycle engines for optimal performance.

Break-In Period for 4-Cycle Engines

Details the break-in period for 4-cycle engines, focusing on careful treatment for longevity.

Starting a Cold Engine

Provides a step-by-step guide for starting a cold engine, including choke and fuel valve usage.

After Engine Starts

Explains how to properly warm up the engine after starting to prevent damage.

Carrying Loads Guidelines

Advises on evenly distributing cargo weight (1/3 front, 2/3 rear) for stable driving.

Load Carrying Safeguards

Lists crucial safeguards for carrying loads, including reducing speed, proper distribution, and securing loads.

Riding Tips

Pre Ride Inspection

Ensures the machine is in proper working order before riding.

Safe Riding Tips - Making Turns

Practice making turns at slow speeds with proper body lean.

Safe Riding Tips - Riding On Slippery Surfaces

Provides advice for riding on slippery surfaces to prevent turnover.

Safe Riding Tips - Traveling Uphill

Guides on traveling uphill safely, emphasizing straight alignment and weight transfer.

Safe Riding Tips - Sidehilling

Warns against sidehilling and provides safety steps if necessary.

Safe Riding Tips - Traveling Downhill

Advises on descending hills safely, focusing on driving straight and weight transfer.

Safe Riding Tips - Turning Around On A Hill

Details the K-turn maneuver for turning around while climbing a hill.

Safe Riding Tips - Crossing Streams

Provides guidelines for safely operating the ATV through water.

Safe Riding Tips - Trail Obstacles

Emphasizes staying alert for hazards like logs and rocks on trails.

Safe Riding Tips - Backing Up

Offers tips for safe backing procedures, including avoiding steep inclines and sharp turns.

Safe Riding Tips - Parking on an Incline

Provides instructions for safely parking the ATV on an incline.

Maintenance and Lubrication

Periodic Maintenance Schedule

Outlines intervals for checks like transmission oil, battery, and engine breather filter.

Detailed Maintenance Schedule

Covers drive chain condition/slack and steering inspection for looseness.

Extended Maintenance Schedule

Specifies monthly checks and annual changes for transmission oil.

Fuel System and Filter Maintenance

Details checks for fuel leaks, fuel valve, filter, pump, and carburetor.

Ignition and Spark Plug Maintenance

Specifies inspection/adjustment of ignition timing and annual fuel filter replacement.

Suspension and Drive Chain Maintenance

Details inspection and tightening of front/rear suspension and drive chain.

Wheel Hub and Bushing Lubrication

Covers lubrication of front drive axle U-joints, ball joints, and A-arm pivot shafts.

Lubrication Recommendations Overview

Recommends Polaris Premium 2-Cycle and 4-Cycle oils, warning against mixing brands.

Brake Fluid and Transmission Oil

Specifies DOT 3 brake fluid and Polaris Premium Synthetic gear case lube for transmission.

Gearcase and Prop Shaft Lubrication

Details lubrication for front gearcase, prop shaft U-joints, and yoke.

Drive Axle and Ball Joint Lubrication

Covers lubrication of rear axle bearings, swing arm bushings, and control arms.

Counterbalance Housing and Steering Bushing Lubrication

Advises checking and changing oil in the counterbalance housing annually.

Rear Axle and Swing Arm Lubrication

Covers lubrication of rear axle bearings, swing arm bushings, and control arms.

Adjustments Overview

Details inspection/adjustment of ignition timing and fuel system checks.

Cooling System and Clutch Adjustments

Covers inspection/replacement of drive belt and steering lubrication.

Suspension and Drive Chain Adjustments

Details inspection and tightening of suspension components and drive chain.

Toe Alignment and Spring Adjustment

Explains how to measure toe alignment and the recommended toe-out specification.

Handlebar Adjustment

Details how to adjust handlebars for personal fit, including bolt torque specifications.

Front Brake System Maintenance

Lists recommended checks for the front brake system, including fluid level and pad wear.

Rear and Auxiliary Brake Maintenance

Advises changing rear brake pads when worn and inspecting disc spline.

Carburetor and Idle RPM Adjustments

Details adjusting the carburetor idle screw for optimal engine RPM on 2-cycle engines.

Carburetor and Throttle Cable Adjustments

Explains adjusting the carburetor idle screw for optimal engine RPM on 4-cycle engines.

Spark Plug Inspection

Describes the appearance of a normal spark plug insulator tip indicating proper operation.

Spark Plug Removal and Replacement

Provides instructions for removing and installing spark plugs, including torque specifications.

Water Service Procedure

Outlines steps to take if the ATV is immersed in water, including drying and dealer service.

Spark Arrestor Maintenance

Lists safety precautions for working with the spark arrestor, emphasizing heat and fire hazards.

PVT System Operation and Safety

Outlines owner responsibilities for PVT system safety, including no modifications and routine maintenance.

PVT Drying Procedure

Provides instructions for drying the PVT system if water has been accidentally ingested.

Battery Maintenance Overview

Explains how to check and maintain battery fluid levels using distilled water.

Battery Removal and Installation

Details the correct order for connecting battery cables to prevent explosions and injury.

Battery Storage and Charging

Advises on removing, charging, and storing the battery in a cool, dry place for long-term storage.

Side Panel Removal (Gen IV Models)

Provides instructions for removing and reinstalling side panels on Gen IV models.

Cleaning Your ATV

Advises on safe ATV washing methods, recommending a garden hose and mild soap.

Waxing and Chemical Precautions

Recommends using non-abrasive paste wax and avoiding harsh cleaners that can scratch the finish.

Storage Tips

Details cleaning, stabilizing fuel, changing oil/filter, and checking fluid levels before storage.

Engine Fogging and Cable Lubrication

Explains fogging the engine with oil for protection during storage.

Battery Maintenance During Storage

Guides on checking battery fluid levels monthly and charging as needed during storage.

Engine Anti-Freeze and Storage Area

Recommends testing engine coolant strength and changing it every two years.

Air Cleaner - 2 Cycle Engines

Details the procedure for removing, cleaning, and reinstalling the air filter and pre-filter.

Cleaning the Main Filter

Explains how to clean the main air filter, including warnings about water immersion.

Breather Filter and Hose Maintenance

Details removing, inspecting, and reinstalling the breather filter and hose.

Steering Inspection

Advises periodic inspection of the steering assembly for loose nuts and bolts.

Toe Alignment Procedure

Explains how to measure toe alignment and the recommended toe-out specification.

Rear Spring Adjustment

Describes adjusting the rear shock absorber spring tension by rotating the adjuster cam.

Handlebar Adjustment Procedure

Details how to adjust handlebars for personal fit, including bolt torque specifications.

Front Brake System Maintenance

Lists recommended checks for the front brake system, including fluid level and pad wear.

Rear and Auxiliary Brake Maintenance

Advises changing rear brake pads when worn and inspecting disc spline.

Carburetor and Idle RPM Adjustments (2 Cycle)

Details adjusting the carburetor idle screw for optimal engine RPM on 2-cycle engines.

Carburetor and Throttle Cable Adjustments

Explains adjusting the carburetor idle screw for optimal engine RPM on 4-cycle engines.

Wheel Removal Procedure

Provides instructions for safely removing ATV wheels, including loosening lug nuts and using a stand.

Wheel Installation Procedure

Details installing wheels, tightening lug nuts according to torque specifications, and checking valve stem position.

Front Wheel Hub Tightening and Tire Inspection

States that front wheel bearing tightness and spindle nut retention require authorized dealer service.

Drive Chain Inspection and Adjustment

Guides on inspecting the drive chain for O-rings and rollers, and lubricating it with proper lube.

Rear Drive Chain Slack Adjustment

Explains how to check and adjust chain slack, specifying the correct deflection amount.

Chain Adjustment Procedure

Provides detailed steps for adjusting rear drive chain tension using eccentric bolts.

Carburetor Adjustments for Altitude/Temperature

Explains how altitude and temperature affect engine performance and potential carburetor adjustments.

Headlight Lamp Replacement

Details how to replace the headlight bulb on Scrambler models.

High Beam Headlight Adjustment

Guides on adjusting headlight aim by measuring distance from the wall and setting beam intensity.

Headlight Lamp Replacement (Trail Blazer)

Instructions for replacing the headlight bulb on Trail Blazer models.

Headlight Lamp Replacement (Gen IV)

Step-by-step guide for replacing the headlight lamp on Gen IV models.

High Beam Headlight Adjustment (Gen IV)

Guides on adjusting headlight aim on Gen IV models using the adjustment knob.

Taillight/Brakelight Lamp Replacement

Details replacing the taillight/brakelight bulb if it is not working.

Spark Plug Inspection

Describes the appearance of a normal spark plug insulator tip indicating proper operation.

Spark Plug Removal and Installation

Provides instructions for removing and installing spark plugs, including torque specifications.

Water Service Procedure

Outlines steps to take if the ATV is immersed in water, including drying and dealer service.

Spark Arrestor Maintenance

Lists safety precautions for working with the spark arrestor, emphasizing heat and fire hazards.

PVT System Operation and Safety

Outlines owner responsibilities for PVT system safety, including no modifications and routine maintenance.

PVT Drying Procedure

Provides instructions for drying the PVT system if water has been accidentally ingested.

Battery Maintenance Overview

Explains how to check and maintain battery fluid levels using distilled water.

Battery Removal and Installation

Details the correct order for connecting battery cables to prevent explosions and injury.

Battery Storage and Charging

Advises on removing, charging, and storing the battery in a cool, dry place for long-term storage.

Side Panel Removal (Gen IV Models)

Provides instructions for removing and reinstalling side panels on Gen IV models.

Cleaning Your ATV

Advises on safe ATV washing methods, recommending a garden hose and mild soap.

Waxing and Chemical Precautions

Recommends using non-abrasive paste wax and avoiding harsh cleaners that can scratch the finish.

Storage Tips

Details cleaning, stabilizing fuel, changing oil/filter, and checking fluid levels before storage.

Engine Fogging and Cable Lubrication

Explains fogging the engine with oil for protection during storage.

Battery Maintenance During Storage

Guides on checking battery fluid levels monthly and charging as needed during storage.

Engine Anti-Freeze and Storage Area

Recommends testing engine coolant strength and changing it every two years.

Air Cleaner - 2 Cycle Engines

Details the procedure for removing, cleaning, and reinstalling the air filter and pre-filter.

Cleaning the Main Filter

Explains how to clean the main air filter, including warnings about water immersion.

Breather Filter and Hose Maintenance

Details removing, inspecting, and reinstalling the breather filter and hose.

Steering Inspection

Advises periodic inspection of the steering assembly for loose nuts and bolts.

Toe Alignment Procedure

Explains how to measure toe alignment and the recommended toe-out specification.

Rear Spring Adjustment

Describes adjusting the rear shock absorber spring tension by rotating the adjuster cam.

Handlebar Adjustment Procedure

Details how to adjust handlebars for personal fit, including bolt torque specifications.

Front Brake System Maintenance

Lists recommended checks for the front brake system, including fluid level and pad wear.

Rear and Auxiliary Brake Maintenance

Advises changing rear brake pads when worn and inspecting disc spline.

Carburetor and Idle RPM Adjustments (2 Cycle)

Details adjusting the carburetor idle screw for optimal engine RPM on 2-cycle engines.

Carburetor and Throttle Cable Adjustments

Explains adjusting the carburetor idle screw for optimal engine RPM on 4-cycle engines.

Wheel Removal Procedure

Provides instructions for safely removing ATV wheels, including loosening lug nuts and using a stand.

Wheel Installation Procedure

Details installing wheels, tightening lug nuts according to torque specifications, and checking valve stem position.

Front Wheel Hub Tightening and Tire Inspection

States that front wheel bearing tightness and spindle nut retention require authorized dealer service.

Drive Chain Inspection and Adjustment

Guides on inspecting the drive chain for O-rings and rollers, and lubricating it with proper lube.

Rear Drive Chain Slack Adjustment

Explains how to check and adjust chain slack, specifying the correct deflection amount.

Chain Adjustment Procedure

Provides detailed steps for adjusting rear drive chain tension using eccentric bolts.

Carburetor Adjustments for Altitude/Temperature

Explains how altitude and temperature affect engine performance and potential carburetor adjustments.

Headlight Lamp Replacement

Details how to replace the headlight bulb on Scrambler models.

High Beam Headlight Adjustment

Guides on adjusting headlight aim by measuring distance from the wall and setting beam intensity.

Headlight Lamp Replacement (Trail Blazer)

Instructions for replacing the headlight bulb on Trail Blazer models.

Headlight Lamp Replacement (Gen IV)

Step-by-step guide for replacing the headlight lamp on Gen IV models.

High Beam Headlight Adjustment (Gen IV)

Guides on adjusting headlight aim on Gen IV models using the adjustment knob.

Taillight/Brakelight Lamp Replacement

Details replacing the taillight/brakelight bulb if it is not working.

Spark Plug Inspection

Describes the appearance of a normal spark plug insulator tip indicating proper operation.

Spark Plug Removal and Installation

Provides instructions for removing and installing spark plugs, including torque specifications.

Water Service Procedure

Outlines steps to take if the ATV is immersed in water, including drying and dealer service.

Spark Arrestor Maintenance

Lists safety precautions for working with the spark arrestor, emphasizing heat and fire hazards.

PVT System Operation and Safety

Outlines owner responsibilities for PVT system safety, including no modifications and routine maintenance.

PVT Drying Procedure

Provides instructions for drying the PVT system if water has been accidentally ingested.

Battery Maintenance Overview

Explains how to check and maintain battery fluid levels using distilled water.

Battery Removal and Installation

Details the correct order for connecting battery cables to prevent explosions and injury.

Battery Storage and Charging

Advises on removing, charging, and storing the battery in a cool, dry place for long-term storage.

Side Panel Removal (Gen IV Models)

Provides instructions for removing and reinstalling side panels on Gen IV models.

Cleaning Your ATV

Advises on safe ATV washing methods, recommending a garden hose and mild soap.

Waxing and Chemical Precautions

Recommends using non-abrasive paste wax and avoiding harsh cleaners that can scratch the finish.

Storage Tips

Details cleaning, stabilizing fuel, changing oil/filter, and checking fluid levels before storage.

Engine Fogging and Cable Lubrication

Explains fogging the engine with oil for protection during storage.

Battery Maintenance During Storage

Guides on checking battery fluid levels monthly and charging as needed during storage.

Engine Anti-Freeze and Storage Area

Recommends testing engine coolant strength and changing it every two years.

Troubleshooting Guides

Engine Start Issues

Provides a flowchart for diagnosing issues when the engine turns over but fails to start.

Engine Power Loss

Offers solutions for when the engine stops or loses power, covering fuel, spark, and overheating.

Clutch and Performance Issues

Addresses issues related to clutch drive belts and covers, including slippage and malfunctions.

General Range Operation Guidelines

Provides guidelines for using Low Range and High Range based on speed and terrain.

Warranty Information

Polaris Limited Six-Month Warranty

Outlines the six-month limited warranty on ATV components against defects in material or workmanship.

Warranty Registration Requirements

Stresses the need for completing an ATV safety training course and proper dealer registration for warranty validity.

Warranty Coverage and Exclusions

Specifies exclusions from the warranty, including accidental damage, abuse, and unauthorized modifications.

How to Obtain Warranty Service

Instructs owners to take the ATV to an authorized Polaris dealer for warranty service with their registration form.

Engine Oil Warranty Requirements

Emphasizes using only Polaris engine oil to maintain warranty coverage and avoid engine damage.

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