2003 Polaris Universal ATV Problems and Repair Information

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Owners Manual - Page 5

... Polaris dealer knows your vehicle best and is outlined in the Polaris Service Manual and should be sure to our world-wide family of your service needs during, and after, the warranty period. Be sure to return to your Polaris vehicle, making it the finest machine we've ever produced. Have your accessories and clothing delivered right...
Owners Manual - Page 9

...vehicles, such as motorcycles and cars. Operator Safety SAFETY WARNING Failure to follow the recommended maintenance program outlined in your area. Read and understand your owner's manual... manual, which includes valuable information about all aspects of vehicle safety. Know Your Vehicle As the operator of our environment. Safety Training When you are thoroughly inspected at specific ...
Owners Manual - Page 48

... N: Neutral L: Low Gear R: Reverse P: Park H N R H L N R P R R P N H L H N 1 L CAUTION Shifting gears with the engine speed above idle or while the vehicle is left unattended, always place the transmission in heavy pulling situations and when operating at less than seven miles per hour for extended periods of the vehicle. Maintaining shift linkage adjustment is important to the desired gear...
Owners Manual - Page 49

.... 2. CAUTION Extending the starter rope too far will allow vehicle operation until the starter mechanism engages. 4. Do not extend the starter rope so far that it stops. The decompressor senses when the engine is spinning fast enough to start the engine. Shift the transmission to start and restores compression for starting possible by allowing...
Owners Manual - Page 52

...Transmission Reverse Indicator (yellow) 4. Transmission Neutral Indicator (green) 2. Oil Warning (red) On 2-cycle models, this page will display if the engine overheats. 6. All Wheel Drive Indicator (red) See page 48 for more information about AWD...'s manual supplement and on this light indicates a low oil level. 5. Turn the key off to prevent battery drain. 4 1 2 5 3 1. Transmission Low...
Owners Manual - Page 54

...: All segments of the instrument cluster. 1. Hour Meter 4. Service Interval/Miscellaneous Service Warnings 5. Driving at start-up for 2.5 seconds at a higher RPM or connecting a battery charger will indicate the gear the machine is in between gears. This warning usually indicates that the transmission switch needs repair. 2. It can, however, also indicate that the ATV...
Owners Manual - Page 60

...brakes - Headlight/Taillight/Brakelight - Engine stop switch - Check for dirt; clean or replace. 10. Loose parts - Visually inspect vehicle for any unusual looseness in ...helmet, goggles and protective clothing. 13. Tires - Check for proper level at the recovery bottle. 58 Riding gear - Check operation of wheel nuts and axle nuts; Wheels - Fuel and oil tanks - Use the following ...
Owners Manual - Page 71

... keeping body weight uphill. 2. Leave transmission in the owner's manual. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to turn around while...Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill. 7. Staying uphill of the vehicle, turn : 1. Restart the engine with the brake, until it down...
Owners Manual - Page 72

...127. OPERATION Driving Safely Driving Through Water Your ATV can result if the vehicle is operated in water that exceeds the recommended maximum depth, go slowly, ...engine oil, transmission oil, front and rear gearcases, and all grease fittings. Choose a crossing 1 where both banks have it serviced as outlined in water, it to have gradual inclines. 3. See page 75. Perform the services...
Owners Manual - Page 78

...-cleaner Coolant level Fuel and oil tanks Throttle Lights Engine stop switch Drive chain Steering " Air box sediment tube Headlamp 76 Perform all services at whichever reading is due at 20 hours, the equivalent odometer reading would be 200 miles. Have an authorized Polaris dealer perform these services. Item Brake System Auxiliary Brake Tires Wheels Frame nuts, bolts...
Owners Manual - Page 81

...Schedule Item J Fuel system MAINTENANCE AND LUBRICATION Hours/ Miles 100 hours Frequency Remarks 12 months Check for leaks at tank cap, lines, fuel valve, filter, pump and carburetor;...24 months 24 months 36 months Radiator Cooling system hoses Spark arrestor " Front hubs (AWD) J Clutches (drive and driven) Engine mounts J Valve clearance L (4-Cycle) J Oil filter (2-Cycle) J Shift selector box...
Owners Manual - Page 82

...Perform all services at 20 hours, the equivalent odometer reading would be 200 miles. Before each ride in wet conditions See Page 91. Frequency As needed, when refueling Check level daily. 2-Cycle Engine 4-Cycle Engine...case lube Polaris Premium Synthetic gear case lube FGrease FGrease (1) Transmission Check every 6 months/1000 miles. Grease fittings. See page 45. Lubrication Chart Key " ...
Owners Manual - Page 88

...if Polaris Premium 4 is 100 hours, 1000 miles, or every six months, whichever comes first.... service. to provide the ultimate in Polaris 4-cycle engines. CAUTION Oil and Filter Change 4-Cycle Engines With...performance and protection. NOTE: See page 141 for use operation requires more power output and lower fuel consumption. Use only 0W-40. It's a fully synthetic, high performance...
Owners Manual - Page 114

... Removal 1. Stop the engine, place the transmission in serious injury or death. MAINTENANCE AND LUBRICATION Adjustments WARNING Operating your owner's manual supplement. Maintain proper tire pressure as described on the decal on your ATV and in your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause...
Owners Manual - Page 121

... of your owner's manual supplement to remove the lower hose from the main filter (2). Wash the pre-filter in the direction of the arrow to check for cracks, deterioration, abrasion, or leaks. Reinstall the filter with Dry Sump NOTE: Refer to your vehicle without a breather filter can cause engine damage. Blow gently through...
Owners Manual - Page 129

...the airbox for service as soon as possible, whether you succeed in starting it if water is not thoroughly inspected. Take the ATV to start . 8. For two cycle engines, reinstall the ... the fuel valve on page 132 for the location. 7. See page 97 for drying out the PVT. 127 Vehicle Immersion MAINTENANCE AND LUBRICATION CAUTION If your vehicle becomes immersed, major engine damage ...
Owners Manual - Page 134

.... See your dealer for service as soon as possible. 132 Start the engine and shift the transmission into the PVT system. Test...with the instructions in this warning can result in the owner's manual. The PVT system rotates at a high speed. Use the... is intended for more than 10 seconds. 3. Take the vehicle to your dealer as the owner, you have the following instructions...
Owners Manual - Page 144

... am- Poor engine performance. Contact your Polaris dealer for damage if repeated leaking occurs. Clutch seals should not be inspected for inspection of control and vehicle overturn. Solution Shift transmission to low range during loading of control and vehicle overturn. in high range. Using the throttle, vary or snow ingestion into the the engine RPM from...
Owners Manual - Page 147

... malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Turn fuel valve to reserve, refuel Inspect and replace Replace with new fuel Inspect, clean and/or replace spark plugs Inspect, clean and/or replace spark plugs See your Polaris dealer Set gap to specs or replace plugs Check all connections and tighten...
Owners Manual - Page 150

... SERVICE If your ATV requires warranty service, you may use of Polaris engine oil. 2. Engine Oil 1. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. however, you must present your dealer to perform warranty service. If any Polaris Servicing Dealer to resolve any additional assistance they will remain in effect. Damage resulting from state to repair...

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