Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Sportsman 550 X2 International
2013
For your nearest Polaris dealer,
visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340 USA
Part No. 9924154 Rev 01
Printed in USA
*9924154 *
GB
D
E
F
I
FI
P
S
Before you operate or ride this vehicle, read the
owner’s manual.
Lesen Sie die Bedienungsanleitung, bevor Sie
dieses Fahrzeug bedienen oder fahren.
Antes de operar o conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel d’utilisation avant d’utiliser ou de
conduire ce véhicule.
Prima di usare o guidare il veícolo, leggere il
Manuale di istruzioni.
Lue aina käyttöohjekirja ennen tämän ajoneuvon
käyttöä tai ajamista.
Antes de utilizar ou andar neste veículo, leia o
Manual do proprietário.
Innan du hanterar eller kör detta fordon, läs
Handboken.
PASSENGER
UNDER
12
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product
introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• RANGER® utility vehicles
• Victory Motorcycles®
• Low emission vehicles (LEVs)
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but informa-
tion about major repairs is outlined in the POLARIS Service Manual
and should be performed only by a factory-certified Master Service
Dealer® (MSD) technician. Please see your dealer for all of your ser-
vice needs during (and after) the warranty period.
2
POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc.
Copyright 2012 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep-
ancies may result between the actual vehicle and the information presented in this publi-
cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
2011 Sportsman 550 X2 International Owner’s Manual
P/N 9924154
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emission Control Systems . . . . . . . . . . . . . . . 70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 127
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 128
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
4
INTRODUCTION
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and sym-
bols are used. Become familiar with their meanings before reading the
manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
5
INTRODUCTION
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the protec-
tion of our environment. Read and understand your owner's manual,
which includes valuable information about all aspects of your vehicle,
including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the opera-
tion of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key
Number
6
SAFETY
Failure to follow the warnings in this manual can result in serious injury or death.
This POLARIS vehicle is not a toy and can be hazardous to operate. A collision
or rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this POLARIS vehicle.
Safety Training
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polarisindustries.com.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Never allow anyone under 16 years of age to operate this vehicle.
Never allow anyone under 12 years of age to ride as a passenger on this
2-up vehicle.
WARNING
7
SAFETY
Restrictions
Towing is approved OFF-ROAD ONLY. Towing a trailer with this vehi-
cle on public roads is prohibited. See your POLARIS dealer about con-
figuring the vehicle to be certified to tow a trailer on-road.
Equipment Modifications
The warranty on your POLARIS vehicle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers and large racks may change vehicle handling. Use only
POLARIS-approved accessories. Know their function and effect on the vehicle.
8
SAFETY
Rider Safety
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the vehicle.
Never operate this vehicle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Never permit others to operate the
vehicle unless they have read and
understand this manual and all
product labels, and have completed a certified safety training course.
Never allow anyone under 16 years
of age to operate this vehicle.
Never allow anyone under 12 years
of age to ride as a passenger on this
2-up vehicle.
Never carry more than one
passenger on this 2-up vehicle.
Do not carry a passenger until you
have at least two hours of driving
experience with this vehicle.
Always wear an approved helmet
that fits properly. Wear eye
protection (goggles or face shield),
gloves, boots, long sleeves and long
pants.
9
SAFETY
Rider Safety
Never consume alcohol or drugs
before or while operating this
vehicle.
Never operate at excessive speeds.
Travel and turn at speeds
appropriate for the terrain, visibility,
operating conditions and your
experience.
Never attempt jumps or other stunts.
Always inspect your vehicle before
each use to verify that it's in safe
operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 49.
10
SAFETY
Rider Safety
Keep both hands on the handlebars.
Keep both feet on the footrests.
A passenger should always be
seated in the passenger seat with
both feet on the footrests and both
hands on the passenger grab handles
at all times. The passenger should
never hold on to the operator.
A passenger riding in the cargo box could fall
from the vehicle unexpectedly or may contact
moving components, both of which can result in
severe injury or death. Never allow a passenger
to ride in the cargo box.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on
rough, slippery or loose terrain.
11
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for turning.
See page 53.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
If the vehicle has been involved in an accident, always have an authorized
POLARIS dealer inspect the entire vehicle for possible damage, including (but
not limited to) brake, throttle and steering systems.
Always follow the procedures
outlined in this manual for driving on
hills. See page 57.
Never operate in TURF mode while
operating on a hill or other irregular
terrain. Always move the 4X4 switch
to ADC 4X4 before ascending or
descending a hill. See page 34.
Never operate on hills too steep for
the vehicle or for your abilities.
Practice on smaller hills before
attempting larger hills. Avoid
climbing hills steeper than 15°.
>15°
12
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for driving
downhill and for braking on hills. See
page 59.
Always descend a hill with the
transmission in forward gear. Do not
descend a hill with the transmission
in neutral.
Never operate in TURF mode while
operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill. See page 34.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 58.
Never attempt to turn the vehicle
around on any hill until you've
mastered (on level ground) the
turning technique outlined in this
manual. See page 60.
Always follow the procedures
outlined in this manual for braking if
you stall or roll backwards while
climbing a hill. Never back down a
hill. See page 60.
13
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for operating
over obstacles. See page 63.
Always follow the procedures
outlined in this manual for operating
on slippery or loose surfaces. Use
extra caution. Always avoid skidding
or sliding. See page 56.
Always follow the procedures
outlined in this manual for driving
through water. Never drive through
deep or fast-flowing water. See page
62.
Always follow the procedures
outlined in this manual for driving in
reverse. See page 64.
14
SAFETY
Rider Safety
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify the vehicle through improper installation or use of accessories.
Never exceed the stated load
capacity for your vehicle. Cargo
must be properly distributed and
securely attached. Reduce speed
and follow the instructions in this
manual for carrying cargo or towing.
See pages 66-69. Allow a greater
distance for braking.
Never operate the vehicle on a
frozen body of water unless you
have independently verified that the
ice is sufficiently thick to support the
weight and moving force of the
vehicle, you and your cargo,
together with any other vehicles in
your party. Variances in snow depth
and/or water currents may result in
uneven ice thickness. Always check
with local authorities and residents to confirm ice conditions and thickness over
your entire route. Vehicle operators assume all risk associated with ice
conditions on frozen bodies of water.
Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.
15
SAFETY
Rider Safety
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before starting the engine. See page 31.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where refu-
eling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an authorized
POLARIS dealer or visit the POLARIS web site at
www.polarisindustries.com.
16
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds estab-
lished safety standards. A passenger (on approved models) should wear
a helmet that includes a rigid chin guard.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
17
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. When-
ever riding a POLARIS vehicle, always wear shatterproof goggles or
use a shatterproof helmet face shield. POLARIS recommends wearing
approved Personal Protective Equipment (PPE) bearing markings such
as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept
clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Rid-
ing pants with kneepads and a jersey with shoulder pads provide the best
protection.
18
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
General
Alert
Age 16
Alert
Hill
Operation
Alert
Reverse
Override
Warning
19
SAFETY
Safety Labels and Locations
General Alert
(Multi-Lingual)
Before you operate or
ride this vehicle, read
the owner’s manual.
7174362
Reverse Override Warning/4X4 Caution
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.
CAUTION
Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
7175512
Hill Operation Alert
• Never operate this vehicle on HILLS steeper than 15 degrees 15°.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and
brakes gradually.
7174361
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa):
Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa)
MAXIMUM WEIGHT CAPACITY 735 lbs.
(333 kg)
INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO AND
ACCESSORIES.
Read Owner’s Manual for more detailed
loading information.
7176783
PASSENGER
UNDER
12
Tire Pressure/Load
Alert
20
SAFETY
Safety Labels and Locations
Rack Warning, Front
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum combined Front Rack and Container Load: 120 lbs. (54 kg)
7175847
Clutch Cover Alert
Clutch Cover
Alert
(under seat)
Rack
Warning
Box
Warning
Hitch
Capacity
Label
21
SAFETY
Safety Labels and Locations
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
Box Warning
WARNING
Remove flammable material
containers from box before filling.
WARNING
Passengers can be thrown off. This
can cause serious injury or death.
Never carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
7173890
22
FEATURES AND CONTROLS
Switches
Main Key Switch
Use the main key switch to start the
engine. See page 51.
End all electrical power to the vehi-
cle.
LIGHTS ON position turns the head-
lights on.
Start the engine. The headlights are
not on in this position.
After starting the engine, release the
key switch to the POSITION LIGHTS ON
position.
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4, 2X4 or TURF
mode. See pages 32-33. The
vehicle automatically engages
4X4 when operating in reverse if
the switch is set to either 4X4
position.
Trip 1
km
mi
RPM
F
E
88
:
88
Main Key
Switch
4X4
Switch
23
FEATURES AND CONTROLS
Switches
Engine Stop Switch
The engine will not start or
run when the switch is in the
OFF position.
OFF
RUN
Push the stop switch down to
stop the engine quickly. Pull
the stop switch up to the
RUN position before attempt-
ing to start the engine.
Both the main switch and the
engine stop switch will shut
off all electrical power to the
vehicle, including lights.
Hazard Switch
Push the hazard warning switch to cause all turn signal lights to
flash simultaneously. Use this feature to alert others of an emer-
gency or other situation requiring caution.
Turn Signal Switch
Push the toggle switch either left or right to activate the corre-
sponding turn signal light. Return the toggle to the center position
to end the signal.
Horn Switch
Press the horn switch to sound the horn.
Momentary High Beam Switch
Press this switch with your left forefin-
ger to activate the headlight high beam.
The lights will return to low beam when
the switch is released.
2x4
T
ri
p 1
km
m
i
R
P
M
F
E
88
:
88
Override
Switch
Engine
Stop
Switch
Headlight
Switch
Horn
Switch
Hazard
Switch
Turn Signal
Switch
Momentary High-Beam
Switch
24
FEATURES AND CONTROLS
Switches
Override Switch/MODE Button
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and press the
override switch.
Pressing the override button while the throttle is open can cause loss of control,
which may result in serious injury or death. Always release the throttle before
pressing the override button.
The reverse override button also acts as a MODE button when held
down for approximately one half second. See the instrument cluster
information beginning on page 38.
Tip: The override button will not function as a MODE button if the transmission
is in reverse.
Headlight Switch
The main key switch must be on and the engine stop switch must be in
the RUN position to operate the headlight switch.
High Beam
Low Beam
25
FEATURES AND CONTROLS
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the vehicle.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate the vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to
increase engine speed and
vehicle movement.
Release the lever to reduce
engine speed and vehicle
movement.
Throttle Release Switch
The throttle release switch causes the engine to stop if the throttle cable
sticks in an open position when the operator releases the throttle lever.
The throttle release switch stops the engine in the event of a throttle system
malfunction. Do not modify the throttle release switch or replace it with other
throttle mechanisms.
26
FEATURES AND CONTROLS
Brake Lever
Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
hydraulically activated disc type
brakes that are activated by only
one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
27
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master
cylinder before each ride.
1. Position the vehicle on a level
surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window
on the top of the master cylin-
der. The eye will appear dark
when the fluid level is full.
When fluid is low, the eye will
be clear.
4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
Master Cylinder
Indicator
Window
28
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
Operating the vehicle while the parking brake is engaged could result in an
accident or fire. Always check to be sure the parking brake is disengaged before
operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the vehicle if leaving it parked on a hill. Another option
is to park the vehicle in a sidehill position. Never depend on the parking
brake alone if the vehicle is parked on a hill. Always block the wheels to
prevent rolling.
29
FEATURES AND CONTROLS
Auxiliary Foot Brake
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems on
this vehicle. Always use caution whenever applying the brakes.
The auxiliary brake system is
intended to be used as a backup for
the main brake system. Should the
main system fail, use the auxiliary
foot brake.
The foot brake operates both front
and rear brakes. The brake is located
on the inside of the right footrest.
Press the brake pedal down with
your foot to apply the brakes.
Brake Fluid Level
Check the brake fluid level fre-
quently for the auxiliary brake sys-
tem. The reservoir is located under
the front storage box. See page 37.
Maintain the fluid level between the
maximum and minimum marks. Use
DOT 4 brake fluid only.
NOTICE: Do not use ADC fluid in the
brake fluid reservoir. ADC
fluid will damage the rubber
components of the brake
system.
Auxiliary
Foot Brake
Brake Fluid
Reservoir
30
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is
located on the right side of the vehi-
cle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
To shift gears, brake to a complete
stop. When the engine is idling, move
the lever to the desired gear.
NOTICE: Shifting gears with the engine
speed above idle or while the vehicle is moving could cause
transmission damage.
Whenever the vehicle is left unattended, always place the transmission
in PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.
Gear
Selector
31
FEATURES AND CONTROLS
Fuel Tank Cap
Remove the fuel tank cap to add fuel
to the fuel tank. Use either leaded or
unleaded gasoline with a minimum
pump octane number of 87=(R+ M/2)
octane. Do not use fuel with ethanol
content greater than 10 percent, such
as E-85 fuel.
Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level sur-
face.
The fuel tank is designed to allow for
the normal expansion of fuel. Do not
overfill. Do not fill the tank neck.
Steering Lock
Lock the steering to prevent unau-
thorized use or theft of the vehicle.
1. Turn the handlebars to the full
right position.
Tip: The handlebars may also be locked
in the full left position.
2. Insert the steering lock key and
turn it clockwise.
3. Remove the key. Place the steer-
ing lock keys in a safe place.
The lock must be replaced if the
keys are lost.
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
2x4
T
r
i
p
1
k
m
mi
R
P
M
F
E
88
:
88
Fuel Tank
Cap
32
FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system is con-
trolled by the 4X4 switch.
ADC 4X4 Mode
When the switch is on ADC 4X4, the
ADC system allows engine braking to
all four wheels when the vehicle
descends a hill or incline. Always
move the 4X4 switch to ADC 4X4
before ascending or descending a hill.
See page 34.
4X4 Mode
When the switch is on 4X4, the vehi-
cle is in 4X4, and the 4X4 indicator
light in the instrument cluster will be
on.
When in 4X4, the demand drive unit
will automatically engage any time
the rear wheels lose traction (in for-
ward or reverse). When the rear
wheels regain traction, the demand
drive unit will automatically disen-
gage. There is no limit to the length of
time the vehicle may remain in 4X4.
4X4 Switch
ADC 4X4
33
FEATURES AND CONTROLS
All Wheel Drive System
2X4 Mode
When the switch is on 2X4, the vehicle is in two-wheel drive at all
times.
TURF Mode
When operating in TURF mode, the inside rear wheel will rotate inde-
pendently from the outside wheel during turns. Operate in TURF mode
only as needed to protect smooth, level surfaces from tire damage. DO
NOT operate in TURF mode when climbing or descending hills, when
sidehilling, or when operating on uneven, loose, or slippery terrain such
as sand, gravel, ice, snow, obstacles, and water crossings. Always oper-
ate in ADC 4X4 or 4X4 on these types of terrain.
Operating in TURF mode when on sloped, uneven, or loose terrain could cause
loss of control and result in serious injury or death. One rear wheel may slip and
lose traction or may lift up and grab when it touches the ground again.
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable 4X4 until the
engine RPM is below 3100. Once enabled, 4X4 remains enabled until
the 4X4 switch is turned off. If the switch is turned off while the demand
drive unit is moving, it will not disengage until the rear wheels regain
traction.
Engage the 4X4 switch before getting into conditions where front wheel
drive may be needed. If the rear wheels are spinning, release the throttle
before switching to 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may
cause severe drive shaft and gearcase damage. Always switch to
4X4 or ADC 4X4 while the rear wheels have traction or are at rest.
34
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the follow-
ing conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (24 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the fol-
lowing conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle speed exceeds 15 mph (24 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
35
FEATURES AND CONTROLS
Passenger Seat
Always make sure the passenger seat lock-out is functioning properly
before operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when oper-
ating without a passenger. Always return the seat to the 1-up position for
single-rider operation.
Never carry cargo in the rear box when operating the vehicle in the 2-up
mode with a passenger.
Seat Conversion
1. Make sure the cargo box dump latch is securely latched. See page
69.
2. Slide the seat latch levers inward to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
Passenger
Backrest
Release Locks
Operator Backrest
Latches
36
FEATURES AND CONTROLS
Passenger Seat
Seat Conversion
5. Lift the adjustment latch at the top of the passenger backrest. Raise
the backrest to the desired position. Release the latch, making sure
it locks into one of the three operating positions.
Tip: The backrest must be moved out of the lowest position before it can be
secured in the upright position. The lowest position is for seat storage only.
Do not leave the backrest in the lowest position. Always adjust the backrest
to one of the three operating positions.
6. Lower the operator backrest
to create the passenger seat.
Two retaining pins under the
seat should fit into the two
grommets on the seat base.
7. Test the passenger seat lock-
out by attempting to release
the cargo box dump latch.
See page 69. If the dump
latch releases, the seat is not
secure. Repeat the set-up
procedure. If the lock-out is
not working properly, do not
allow a passenger to ride the
vehicle. See your POLARIS
dealer for service.
8. To return the vehicle to single-rider
operation, reverse all steps. Always
lower the passenger backrest to the
lowest position before folding it
down into the cargo box. Slide the
seat latch levers outward to secure the
locks.
Passenger
Backrest
Adjustment
Latch
Locked
37
FEATURES AND CONTROLS
Front Box/Compartment
Release the front box anchor latches
and remove the box assembly to gain
access to the front compartment. To
reinstall the box, hold the box as
shown in the rack illustration. Posi-
tion the front edge in the tabs, then
push the box downward and secure
the latches.
Access the following components in
the front compartment:
• Radiator cap
• Brake fluid reservoir
• ADC fluid reservoir
• Battery
• Coolant recovery bottle cap
• Electrical/fuse/relay components
Latches
ADC Fluid
Reservoir
Brake Fluid
Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
Battery
38
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage vehicle components. Wash the
vehicle by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
Digital/Analog Gauge
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH)
or kilometers per hour (km/h).
Trip 1
km
mi
RPM
FE
88
:
88
Rider
Information
Center
Speedometer
Indicator Lamps
39
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Indicator Lamps
Lamp Indicates Condition
Vehicle
Speed
When standard mode is selected, speed displays in
miles per hour.
When metric mode is selected, speed displays in
kilometers per hour.
Over
Temperature
This lamp flashes to indicate an overheated engine. If
the indicator stops flashing but remains illuminated,
the overheating condition remains, and the system
will automatically reduce engine power.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is
set to high beam.
Direction
Indicators
A direction indicator flashes when a turn signal is
active. Both indicators flash when the hazard signal is
active.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.
40
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All seg-
ments will light up for one second at start-up. If the instrument cluster
fails to illuminate, a battery over-voltage may have occurred and the
instrument cluster may have shut off to protect the electronic speedome-
ter. If this occurs, take the vehicle to your POLARIS dealer for proper
diagnosis.
The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 43.
Trip 1
km
mi
RPM
FE
88
:
88
1
2
6
5
7
3
4
8
41
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
1. Gear Display - This area displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
2. Fuel Gauge Display - The segments of the fuel gauge show the
level of fuel in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments including the fuel icon will
flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the
fuel sensor circuit. See your dealer.
3. Information Display - This area displays odometer, trip meter,
engine hour meter, engine speed and programmable service hour
interval.
4. Active Descent Control Display - This icon displays when ADC is
active. See page 34.
5. Clock Display - The clock displays time in a 12-hour or 24-hour
format. If the engine is turned off, press the MODE button. The
time will display for 5-10 seconds. See page 43 for resetting instruc-
tions.
6. Service Reminder Display - A flashing wrench symbol alerts the
operator that the preset service interval has been reached. The vehi-
cle should be brought to your dealer for scheduled maintenance. See
page 43 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 or 4X4).
8. Turf Mode Indicator - This icon displays when Turf Mode is
engaged.
42
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The reverse override button acts as the MODE button when pressed and
released quickly. The transmission cannot be in reverse when using the
override button as a MODE button. This feature does not contain a vehi-
cle speed lockout function and can be used at any operating speed.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric units of
measurement.
Tip: To exit the set-up mode at any time, wait 10 seconds.The display automati-
cally exits and returns to the odometer display.
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON
position.
4. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to
the next display option.
6. Repeat the procedure to change remaining display settings.
Standard Display Metric Display
Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock
43
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or dis-
charged.
1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meter records the distance traveled by the vehicle if reset before
each trip. To reset, select the trip meter mode. Press and hold the MODE
button until the meter resets to zero. In the Rider Information Center, the
trip meter display contains a decimal point, but the odometer displays
without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
44
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Programmable Service Interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is pro-
grammed at 50 hours at the factory. Use the following procedure to
change the service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the deter-
mination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
45
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Engine Error Codes
The error screen displays
only when the CHECK
ENGINE light is on or when
it goes on and off during one
ignition cycle. Error codes
are not stored in the gauge
when the key is turned off.
The code and message is
lost, but will reappear if the
fault reoccurs after restart-
ing the engine.
If the CHECK ENGINE
light illuminates, retrieve
the error codes from the dis-
play. Please see your
POLARIS dealer for all major repairs.
1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code
menu.
3. Record the numbers displayed in the gear position (if any), clock
and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 46-47 for code definitions and failure descriptions. Please
see your POLARIS dealer for all major repairs.
Suspect Parameter
Number (SPN)
Error Code
Number (0-9)
Failure Mode Indicator (FMI)
46
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground:
The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load:
The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery:
The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
47
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
*Assumes unipolar configuration of stepper motor
Sportsman 550 X2 Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor
Voltage Too High 51 3
Voltage Too Low 51 4
Engine Temperature Sensor
Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0
Intake Air Temperature Sensor
Voltage Too High 105 3
Voltage Too Low 105 4
Manifold Absolute Pressure Sensor
Voltage Too High 102 3
Voltage Too Low 102 4
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4
Voltage Too High 523 3
Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5
Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
Idle Air Control Driver Circuit Grounded 520193 5
Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
48
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS vehicle is the first 20 hours
of operation. No single action on your part is as important as following
the procedures for a proper break-in. Careful treatment of a new engine
and drive components will result in more efficient performance and lon-
ger life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 31. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 76. Add oil if
necessary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to famil-
iarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 49.
6. Pull only light loads.
7. Change both the oil and the filter at 25 hours.
8. Check the fluid level of the transmission after the first 25 hours of
operation and every 100 hours thereafter.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur-
ing the break-in period.
If a belt fails, always clean away all debris when replacing the belt.
WARNING
49
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the vehicle is in safe operating condi-
tion before operating increases the risk of an accident. Always inspect
the vehicle before each use to make sure it's in safe operating condition.
Item Remarks Page
Passenger seat lock-out Ensure proper operation 35
Brake system/lever travel Ensure proper operation 26
91
Brake fluid Ensure proper level 27
Auxiliary brake Ensure proper operation 29
Front suspension Inspect, lubricate if necessary 75
Rear suspension Inspect, lubricate if necessary 75
Steering Ensure free operation -
Steering lock Unlock the steering; ensure free oper-
ation
31
Tires Inspect condition and pressure 94
Wheels/fasteners Inspect, ensure fastener tightness 94
95
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 31
76
Coolant level Ensure proper level 89
90
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 25
114
Switches Ensure operation 22
Engine stop switch Ensure proper operation 23
Mirrors Adjust for best side/rear vision 25
Turn signals, indicators Ensure operation 23
Air filter, pre-filter Inspect, clean 96
Headlamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
24
100
Brake light/taillight Check operation, apply POLARIS
dielectric grease when lamp is
replaced
102
Riding gear Wear approved helmet, goggles, and
protective clothing
16
ADC Fluid Ensure proper level 84
50
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to oper-
ate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre-
quently and replace burned out headlamps promptly.
5. Drive in a manner appropriate for your skills, your passenger’s
skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your
hands from the handlebars while operating, and always keep both
feet on the footrests.
6. Never consume alcohol or drugs before or while operating this vehi-
cle.
7. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
8. Never operate a damaged vehicle. After any overturn or accident,
have a qualified service dealer inspect the entire machine for possi-
ble damage.
9. Never operate the vehicle on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the
weight and moving force of the vehicle, you and your cargo,
together with any other vehicles in your party.
10. Do not touch hot exhaust system components. Always keep com-
bustible materials away from the exhaust system.
11. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
51
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-venti-
lated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
Tip: Do not press the throttle while starting the engine.
5. Turn the ignition key past the POSITION
LIGHTS ON position to engage the starter.
Activate the starter for a maximum of five
seconds, releasing the key when the engine
starts.
6. If the engine does not start, return the key to
the OFF position and wait five seconds before
attempting to start again. Activate the starter
for another five seconds if necessary. Repeat
this procedure until the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water accu-
mulation increases as outside temperature decreases.
If a belt fails, always clean away all debris when replacing the belt.
52
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 16.
2. Perform the pre-ride inspection. See page 49.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the
handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
53
OPERATION
Turning the Vehicle
1. Before turning, activate
a turn signal to alert oth-
ers of your intentions.
Activate the left signal
before a left turn. Acti-
vate the right signal
before a right turn.
2. Steer in the direction of
the turn, leaning your
upper body to the inside
of the turn while sup-
porting your weight on
the outer footrest. Use
the same leaning tech-
nique for turning in
reverse.
3. Practice making turns at
slow speeds before
attempting to turn at faster speeds.
Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp
angles. Never turn at high speeds.
54
OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on
this 2-up vehicle. Make sure any passenger is tall enough to com-
fortably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear, includ-
ing an approved helmet with a rigid chin guard. See page 16.
4. Perform the pre-ride inspection. See page 49.
5. Convert the seat for 2-up riding. See page 35. Always make sure the
passenger seat lock-out is functioning properly before carrying a
passenger.
6. Lock the parking brake.
7. Mount the vehicle from the left side. After the operator is seated, the
passenger should mount the vehicle from the left side. Always make
sure the brake is engaged to ensure the vehicle remains motionless
whenever a passenger mounts or dismounts.
8. Allow a passenger to ride only in the approved passenger seat.
9. Never carry more than one passenger.
10. Slow down. Control may be more difficult with a passenger on
board. Allow more time and distance for braking.
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a pas-
senger to fall from the vehicle.
55
OPERATION
Driving with a Passenger
12. Do not cross a hillside with
a passenger on board. See
page 58.
13. A passenger should always
be seated in the passenger
seat with both feet on the
footrests and both hands on
the passenger grab handles
at all times. The passenger
should never hold on to the
operator.
14. Make sure the passenger
understands the importance
of "active riding." When
hill-climbing or perform-
ing maneuvers, a passenger should shift body weight in the same
manner in which the driver shifts body weight. For example, the
passenger should lean to the inside of a turn along with the operator
and should always lean uphill when climbing and descending hills.
56
OPERATION
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails,
gravel, snow or ice, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
4. Be alert. Watch the trail. Avoid quick, sharp turns
5. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
Sideways
skid
Turn in
direction of
skid
57
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
2. Drive straight uphill.
3. Avoid steep hills (15° maximum).
4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill. A passenger should also shift body weight
uphill.
8. Proceed at a steady rate of speed to avoid stalling.
9. Never open the throttle suddenly or make sudden gear changes.
10. Be alert. Be prepared to take emergency action. This may include
dismounting quickly.
15° Maximum
58
OPERATION
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.
3. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.
4. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
59
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
3. Always descend a hill with the transmission in forward gear. Do not
descend a hill with the transmission in neutral.
4. Slow down. Never travel down a hill at high speed.
5. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.
6. Shift body weight uphill. A passenger should also shift body weight
uphill.
7. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss
of control.
15° Maximum
60
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
61
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then
the operator may dismount. Dismount on the uphill side of the vehi-
cle, or on the left if the vehicle is pointing straight uphill. A passen-
ger should not remount until the vehicle returns to firm, level
ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point-
ing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill. A passenger should not remount until
the vehicle returns to firm, level ground.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
62
OPERATION
Driving Through Water
Follow these procedures when driving through water:
1. Check water depth and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Drive slowly. Avoid rocks and obstacles.
4. Avoid operating in water deeper than the bottom of the footrests. If
it's unavoidable, travel slowly, balance your weight carefully and
avoid sudden movements. Maintain a slow and steady forward
motion. Do not make sudden turns, stops or throttle changes.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 71. The following areas need
special attention: engine oil, transmission oil, demand drive fluid and
all grease fittings
.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 105,
then see your dealer for service at the first opportunity.
5. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
Maximum Depth
63
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
5. Always have a passenger dismount before operating over an obsta-
cle that could cause a fall from the vehicle or vehicle tipover.
64
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Be aware
that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Drive slowly. Apply the brakes lightly for stopping.
4. Avoid turning at sharp angles.
5. Never open the throttle suddenly.
6. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use with caution.
NOTICE: Excessive throttle operation while in the speed limit mode may cause
fuel to build in the exhaust, resulting in engine popping and/or engine
damage.
65
OPERATION
Parking on an Incline
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
66
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
• Read and understand the load distribution warnings listed on the vehicle
warning labels.
• Never carry cargo in the rear box when operating the vehicle in the 2-up
mode with a passenger.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
• Never exceed the stated load capacity for this vehicle. When determining the
weight you are adding to the vehicle, include the weight of the operator,
passenger, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.
• WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as
low as possible. Carrying a high load raises the center of gravity and creates
a less stable operating condition. Reduce load weight when cargo is high.
When handling off-centered loads that cannot be centered, secure the load
and operate with extra caution. When operating over rough or hilly terrain,
reduce speed and cargo to maintain stable driving conditions.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift
and create unstable operating conditions, which could result in loss of control
of the vehicle. Always be sure that the cargo bed is lowered and latched
before moving the vehicle.
• USE EXTREME CAUTION when operating with loads extending beyond the
rack or cargo bed. Stability and maneuverability may be adversely affected,
causing the machine to overturn.
• BALANCE LOADS proportionally between the front rack and cargo bed, but
do not exceed the stated load capacity. Carrying a load on only the front rack
or cargo bed may cause an imbalanced condition and increases the
possibility of vehicle overturn.
• USE EXTREME CAUTION when applying brakes with a loaded vehicle.
Avoid terrain or situations that may require backing downhill.
• Always attach the tow load to the hitch point designated for your vehicle.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 50
MPH (80 km/h) while carrying a passenger. NEVER exceed 10 MPH (16 km/
h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads
are above 100 lbs. (45 kg).
• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when
towing loads in rough terrain, while cornering, or while ascending or
descending hills.
• TOWING is approved OFF-ROAD ONLY.
• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on
the front rack.
67
OPERATION
Hauling Cargo
Never exceed the weight
capacities specified for your
vehicle on warning labels
and in the specifications sec-
tion of this manual.
1. Cargo weight should be
mounted as low as pos-
sible.
2. When operating over
rough or hilly terrain,
reduce speed and cargo
weight to maintain sta-
ble driving conditions.
3. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above
75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
4. NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
5. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above
200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
6. Always load the cargo box with the load as far forward as possible.
7. Do not obstruct the headlight beam with cargo.
8. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
9. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
10. Slow down.
11. Make sure the cargo box dump latch is securely latched before load-
ing and operating. Unintentional dumping will result if weight is
placed in the rear of the box and the latch is not secured.
68
OPERATION
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY. See your POLARIS dealer
about configuring the vehicle to be certified to tow a trailer on-road.
• Do not tow any trailer on a grade steeper than 15°.
• Always attach a towed load to the hitch point. Remove the hitch from
the vehicle when not towing a trailer. If towing a load, reduce rear
box cargo weight by the amount of tongue weight.
• The combination of rear box cargo weight and tongue weight must
not exceed the rear box capacity.
• The total load (operator, passenger, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your POLARIS
warranty. Never install a hitch longer
than 10 cm. Never install automotive
accessories on your POLARIS
vehicle. Always install POLARIS-
approved (or equivalent) accessories
designed for use on this vehicle.
Do not exceed the following maximum capacities when towing. Avoid
towing on inclines.
Maximum Towing Capacities
Maximum Towed Load (Level Ground) 1500 lbs. (680 kg)
Maximum Vertical Hitch Weight 150 lbs. (68 kg)
Maximum
4" (10 cm)
69
OPERATION
Hauling Cargo
Dumping Cargo
1. Select a level site to dump the cargo box. Do not attempt to dump or
unload the vehicle while parked on an incline.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Dismount the vehicle.
5. Lower the tailgate.
If cargo weight is placed toward the rear of the cargo box, the load may dump
unexpectedly and cause serious injury. When loading cargo, always position the
weight as far forward and as low as possible.
6. Pull the cargo box release
strap upward.
7. Lift the front of the cargo
box and dump the cargo.
8. Lower the cargo box and
make sure the release latch
is secured.
9. Secure the tailgate.
Operating with the cargo box in the raised position can cause serious injury and
damage to the vehicle. The cargo box could close unexpectedly and injure the
driver. The rear tires will also catch the rear of the bed, damaging the vehicle
and creating hazardous driving conditions. Never operate this vehicle with the
cargo box in the raised position.
Cargo Box
Release Strap
70
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compli-
ance with governmental noise level requirements.
Spark Arrestor
Your POLARIS vehicle has a spark arrestor that was designed for on-road and off-road
operation. It is required that this spark arrestor remain installed and functional when the
vehicle is operated.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI)
system controls fuel delivery. The engine and EFI components are set at the factory for
optimal performance and are not adjustable.
Electromagnetic Interference
This spark ignition system complies with Canadian standard ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and
2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with
active or non-active implantable medical devices (such as heart monitoring or control-
ling devices) should review the limitations of their device and the applicable electro-
magnetic standards and directives that apply to this vehicle.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated
by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors,
including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
71
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe, reli-
able condition. Inspect, clean, lubricate, adjust and replace parts as nec-
essary. When inspection reveals the need for replacement parts, use
genuine POLARIS parts available from your POLARIS dealer. Record
maintenance and service in the Maintenance Log beginning on page
135.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average rid-
ing conditions and an average vehicle speed of approximately 10 miles
per hour. Vehicles subjected to severe use must be inspected and ser-
viced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or crank-
case. Change oil immediately if the oil level begins to rise. Monitor the
oil level, and if it continues to rise, discontinue use and determine the
cause or see your dealer.
72
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a “D” could result in
component failure and lead to serious injury or death. Have an authorized
POLARIS dealer perform these services.
Maintenance Chart Key
Perform all services at whichever maintenance interval is reached first.
Symbol Description
Perform these operations more often for vehicles subjected to severe use.
E Emission-related service.
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
Make adjustments as
needed. See Pre-Ride
Checklist on page 49.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake lever travel - -
Brake system - -
Passenger seat
lock-out
--
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Coolant - Daily - Check level daily, change
coolant every 2 years
ADC fluid - Daily - Check level daily, add as
needed
Headlight/taillight - Daily - Check operation; apply
dielectric grease if replacing
lamps
73
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
E
Air filter,
main element
- Weekly - Inspect; replace as needed
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change
Demand drive fluid
(extreme use)
25 H 1 M 250 (400) Change fluid every 25 hours
if ADC is subjected to
extreme use. See page 82.
Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check
Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check
Transmission oil 25 H 1 M 250 (400) Break-in oil level check
General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Shift linkage 50 H 6 M 500 (800) Inspect, lubricate
D Steering 50 H 6 M 500 (800) Lubricate
Front suspension 50 H 6 M 500 (800) Lubricate
Rear suspension 50 H 6 M 500 (800) Lubricate
D
E
Throttle Cable/
Throttle Release
Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper seal-
ing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
Radiator 50 H 6 M 1000 (1600) Inspect; clean external
surfaces
Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks
Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
Demand drive fluid
(normal use)
100 H 12 M 1000 (1600) Change fluid
Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid
Transmission oil 100 H 12 M 1000 (1600) Change fluid
74
MAINTENANCE
Periodic Maintenance Chart
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
D
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
D
ADC fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
D
E
Valve clearance 1000 H - 10000
(16000)
Inspect; adjust
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
75
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Peri-
odic Maintenance Chart beginning on page 71. Items not listed in the
chart should be lubricated at the General Lubrication interval.
The a-arms and upper control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Item Recommended
Lubricant
Capacity
at Fluid
Change
Fill Plug
Torque
Drain Plug
Torque
Inspection
Procedure
Engine Oil PS-4 PLUS
Performance
Synthetic 2W-50
2 qt.
(1.9 l)
--- 15-17 ft. lbs.
(20-23 Nm)
Page 76.
Transmission
Oil
AGL PLUS
Transmission
Fluid
32 oz.
(950 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 80.
Demand Drive
Fluid (Front
Gearcase)
Demand Drive
Plus Fluid
9.3 oz.
(275 ml)
8-10 ft. lbs.
(11-14 Nm)
11 ft. lbs.
(15 Nm)
Page 82.
Rear
Gearcase Oil
ATV Angle Drive
Fluid (or GL5 80-
90 weight gear
lube)
6.1 oz.
(180 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 86.
Brake Fluid DOT 4 Only --- --- --- Page 27.
ADC Fluid Demand Drive
Plus Fluid
--- --- --- Page 84.
Front Prop
Shaft Yoke
POLARIS
Premium U-Joint
Lube
Grease fittings (3 pumps maximum) every 500 miles,
before long periods of storage, or after pressure
washing or submerging.
A-Arms, Front
and Rear
POLARIS
Premium All-
Season Grease
Grease fittings after extreme use or if suspension
becomes squeaky.
Front Prop Shaft Yoke
Front
76
MAINTENANCE
Engine Oil
Oil Recommendations
POLARIS recommends the use of POLARIS PS-4 PLUS Performance
Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table
on page 75 for fluid recommendations, capacities and plug torques.
Oil may need to be changed more frequently if POLARIS oil is not
used. Always use 2W-50 oil. Follow the manufacturer's recommenda-
tions for ambient temperature operation. See page 127 for the part num-
bers of POLARIS products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute
or mix oil brands.
77
MAINTENANCE
Engine Oil
Oil Level
Check the oil level when the engine is cold. Never check the oil with the
engine running.
1. Position the vehicle on a level surface.
2. Access the oil dipstick and fill tube from the left side of the vehicle.
Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall and tighten the dipstick.
4. Remove the dipstick and check the oil level.
5. Add the recommended fluid as needed. Maintain the oil level in the
safe range between the FULL and ADD marks. Do not overfill.
6. Reinstall and tighten the dipstick.
Dipstick
Full Add
78
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 75 for fluid recommendations, capacities and plug
torques. Always change the oil and filter at the intervals outlined in the
Periodic Maintenance Chart beginning on page 71. Always change the
oil filter whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three min-
utes.
3. Stop the engine.
4. Clean the area around the drain plug.
5. Place a drain pan under the crankcase.
6. Remove the drain plug. Allow the oil to drain completely.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to specification.
Drain Plug
to front
Filter Access
79
MAINTENANCE
Engine Oil
Oil and Filter Change
9. Place shop towels beneath the oil filter.
Using an oil filter wrench (available from
your POLARIS dealer), turn the filter
counterclockwise to remove it.
10. Using a clean dry cloth, clean the filter
sealing surface on the crankcase.
11. Lubricate the o-ring on the new filter
with a film of fresh engine oil. Check to
make sure the o-ring is in good condition.
12. Install the new filter and rotate it clock-
wise by hand until the filter gasket con-
tacts the sealing surface, then turn it an
additional 1/2 turn.
13. Remove the dipstick. Add the proper
amount of the recommended oil. Do not
overfill.
14. Reinstall the dipstick.
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
21. Dispose of used filter and oil properly.
Oil Filter
80
MAINTENANCE
Transmission Oil
POLARIS recommends the use of POLARIS AGL PLUS Transmission
Fluid for this transmission. See the table on page 75 for fluid recom-
mendations, capacities and plug torques. Always check and change the
transmission oil at the intervals outlined in the Periodic Maintenance
Chart beginning on page 71. See page 127 for the part numbers of
POLARIS products.
Maintain the oil level at the bottom of the fill plug hole. The fill plug is
located on the right side of the vehicle behind the footwell. The drain
plug is located on the bottom left side of the gearcase.
Oil Check
1. Remove the footwell (see
page 93).
2. Remove the fill plug. Check
the oil level.
3. Add the recommended fluid
as needed to bring the level to
the bottom of the fill hole
threads.
4. Reinstall the fill plug. Torque
to specification.
5. Reinstall the footwell.
Drain Plug
Fill Plug
Fill
Level
81
MAINTENANCE
Transmission Oil
Oil Change
1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug. Add the proper amount of the recommended
oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
8. Dispose of used oil properly.
82
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 75 for fluid recommendations, capacities and plug
torques. Always check and change the demand drive fluid at the inter-
vals outlined in the Periodic Maintenance Chart beginning on page 71.
NOTICE: Change the demand drive fluid every 25 hours if the ADC unit is
exposed to extreme use.
ADC Extreme Use Definition
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. See page 127 for the part numbers of
POLARIS products.
Maintain the fluid level at
the bottom of the fill hole
threads. See below for
capacity. The fill plug is
located on the right side of
the demand drive unit. The
drain plug is located on the
bottom right side of the
unit.
Drain Plug
Fill
Plug
Fill
Level
83
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Check
1. Position the vehicle on a level surface. Remove the fill plug. Check
the fluid level.
2. Add the recommended fluid as needed to bring the level to the bot-
tom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain
plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
84
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Level
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 71.
We recommend the use of POLARIS Demand Drive Plus Fluid for the
ADC unit. Maintain the fluid level between the minimum and maximum
marks on the reservoir. See page 127 for the part numbers of POLARIS
products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
1. Remove the front box.
2. View the fluid level in the
reservoir.
3. If the level is below the
minimum mark, remove
the cap and add the
recommended fluid.
4. Reinstall the cap.
5. Reinstall the front box.
ADC Fluid
Reservoir
85
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Change
1. Position the vehicle on a level
surface. Before performing the
fluid change, allow the vehicle
to sit for at least 30 minutes.
2. Thoroughly clean the areas
around and on the ADC
reservoir and bleeder valves
(one on each side of the
differential).
3. Remove the reservoir cap and
diaphragm assembly. Use a
shop towel or suction tool to
remove debris from the fluid
and reservoir. Debris in the
reservoir may result in
inadequate bleeding and
reduced performance of the
system.
4. Fill the reservoir to the maximum line with fresh fluid.
5. Remove the protective caps from the bleeder valves.
6. Slowly loosen one of the bleeder valve screws (turn counter-clock-
wise) and allow fluid and trapped air to flow from the fitting.
Tighten the screw when clean fluid begins to flow. Repeat this step
for the remaining valve.
IMPORTANT: Close the bleeder valve screws before the reservoir fluid level
drops below the minimum fill line. Adding fluid to an empty reservoir will result in
trapped air. If the level drops below the minimum line, add fluid to the maximum
line and repeat step 6 before proceeding.
7. Torque the bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the
bleeder valve caps.
8. Add fresh ADC fluid to the reservoir until the level is between the
minimum and maximum marks. Make sure the reservoir is free of
debris.
9. Reinstall the cap securely. Clean up any drips or spills.
Bleeder
Screw
Cap
Bleeder
Valve
Screw
86
MAINTENANCE
Rear Gearcase Oil
See the table on page 75 for fluid recommendations, capacities and plug
torques. Always check and change the rear gearcase oil at the intervals
outlined in the Periodic Maintenance Chart beginning on page 71. See
page 127 for the part numbers of POLARIS products.
The fill plug is located on the
rear of the gearcase. The drain
plug is located on the bottom
of the gearcase.
Maintain the fluid level at the
bottom of the fill hole threads.
Do not overfill.
Oil Check
1. Position the vehicle on a
level surface.
2. Remove the fill plug.
Check the oil level.
3. Add the recommended oil
as needed to bring the
level to the bottom of the
fill hole threads. Do not overfill.
4. Reinstall the fill plug. Torque to specification.
Drain Plug
Fill Plug
Fill
Level
87
MAINTENANCE
Rear Gearcase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
5. Remove the fill plug. Add the proper amount of the recommended
oil. Do not overfill.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
88
MAINTENANCE
Cooling System
The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the con-
tracting (cooled) coolant is drawn back up from the bottle, past the pres-
sure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS Premium 60/40 anti-
freeze/coolant or a 50/50 mixture of high quality aluminum compatible
anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is
already premixed and ready to use. Do not dilute with water. See page
127 for the part numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
89
MAINTENANCE
Cooling System
Recovery Bottle Coolant
The recovery bottle fluid level can be viewed from inside the front right
wheel well. Access the recovery bottle cap under the front storage com-
partment.
1. View the fluid level in the bottle.
2. If the level is low, remove the front box.
3. Remove the bottle cap and add coolant as needed. Maintain the
coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool).
4. Reinstall the cap.
5. Reinstall the front box.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
90
MAINTENANCE
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine,
POLARIS recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.
Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. Add coolant as needed.
Escaping steam can cause burns. Never remove the pressure cap while the
engine is warm or hot. Always allow the engine to cool before removing the
pressure cap.
1. Remove the front box.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant
through the radiator filler neck.
4. Reinstall the pressure cap. Use of a
non-standard pressure cap will not
allow the recovery system to func-
tion properly. Contact your dealer
for the correct replacement part.
5. Reinstall the front box.
Radiator
Cap
91
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self-
adjusting.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in serious injury or death. Maintain brake fluid at the recommended level.
Do not overfill.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an adequate
level. See page 27.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc. Clean any grease using a rec-
ommended brake cleaner or alcohol. Do
not use spray lubricants or other petroleum-based products. If you
discover any damage (cracks, excessive corrosion, warping) see
your dealer for service before operating.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 29.
3/64" (1 mm)
92
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/4-1/2 inch (6-12 mm) toe out.
Severe injury or death can result from improper toe alignment and adjustment.
Do not attempt to adjust tie rod alignment. All tie rod adjustments should be
performed by an authorized POLARIS dealer.
1. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straight-
edge instead of string.
4. Measure the distance
from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/8-1/4 inch (3-6 mm) more than the front measurement
on each side of the vehicle to obtain the recommended 1/4-1/2 inch
(6-12 mm) toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for
service.
Steering Assembly
The steering assembly of the vehicle should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
String
Stand
2
1
93
MAINTENANCE
Seat Removal
1. Remove any cargo from the
cargo box before removing the
seat.
2. Stand beside the vehicle. Pull
the cargo box release strap
upward. Lift the front of the
cargo box.
3. Grasp edge of the seat near the
opposite rear corner.
4. Pull upward abruptly to disen-
gage the under-seat fasteners.
5. Remove the seat.
Side Panel/Footwell Removal
1. Remove the seat before removing a side panel.
2. To remove a side panel or footwell, remove the fasteners securing it
to the frame. Lift the right side panel upward while removing it to
clear the shifter knob.
Plastic Rivet
Hex Head Screw
Plastic Rivet
Screw
94
MAINTENANCE
Tires
Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 128 for recom-
mended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical com-
ponent operations. All service must be performed by your authorized
POLARIS dealer.
Wheel Removal
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
Do not service axle nuts that have a cotter pin installed. See your POLARIS
dealer.
5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
1/8" (3 mm)
95
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation (if
equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Loose nuts could cause a tire to come off during operation, which could result in
an accident or overturn. Always ensure that all nuts are torqued to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been loos-
ened for service.
Wheel Type Nut Type Nut Torque
Aluminum Lug Nut 75 ft. lbs. (102 Nm)
Steel Lug Nut 45 ft. lbs. (61 Nm)
Cast Aluminum
Steel
75 ft. lbs.
(102 Nm)
45 ft. lbs.
(61 Nm)
96
MAINTENANCE
Air Filter
1. Remove the seat. See page 93.
2. Remove the air box cover
strap, and remove the air box
cover.
3. Remove the filter.
4. Remove the fabric type pre-
filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.
6. Reinstall the filter into the air
box.
7. Reinstall the air box cover
and the seat.
Main
Filter
Pre-Filter
Strap
97
MAINTENANCE
Fuse Replacement
If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short cir-
cuits that may have caused the blown fuse, then replace the fuse. Spare
fuses are provided in the fuse box.
1. Remove the front box.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown,
install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the front box.
Fuse Box
98
MAINTENANCE
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.
5. Tighten or loosen the three (3)
headlight screws to adjust the
beam upward or downward or
to the left or right.
2" (5 cm)
Lamp Center Height
25 ft. (7.6 m)
Adjustment
Screws
99
MAINTENANCE
Lights
Headlight Housing Replacement
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the speedometer
harnesses from the
speedometer.
3. Unplug the headlamp from
the wiring harness.
4. Use a small screwdriver to
remove the o-rings from the
headlight mounting tabs.
5. Pull the headlight housing up
to release it from the locking
tabs.
6. Carefully pull the assembly up and out of the pod.
7. Reverse the steps to install the new housing and reassemble the pod.
Front Turn Signal Replacement
If a front turn signal light becomes
inoperable, the lamps cannot be
replaced. Replace the entire signal lamp
assembly.
100
MAINTENANCE
Lights
Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.
Hot components can cause serious burns to skin. Do not service the headlamps
until they've cooled.
Headlight Lamp Replacement
When servicing a halogen
lamp, avoid touching the
lamp with bare fingers. Oil
from your skin leaves a resi-
due, causing a hot spot that
will shorten the life of the
lamp. If fingers do touch a
lamp, clean it with denatured
alcohol.
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the speedom-
eter harnesses from the speedometer.
Hot components can cause burns to skin. Allow lamps to cool before servicing.
3. Unplug the headlamp from the wiring harness. Be sure to pull on the
connector, not on the wiring.
4. Turn the lamp counterclockwise to remove it.
5. Install the new lamp. Make sure the tab on the lamp locates properly
in the housing.
6. Reassemble the pod.
101
MAINTENANCE
Lights
Headlight/Position Light Lamp Replacement
When servicing a halogen lamp, do
not touch the lamp with bare fingers.
Oil from your skin leaves a residue,
causing a hot spot that will shorten
the life of the lamp. Hold the plastic
part of the lamp.
1. Place the transmission in PARK.
2. Open the front rack cover.
3. Remove the plug at the back of the
headlight.
4. Pull the harness plug to disconnect
it from the back of the headlight.
5. Position light: Rotate the socket to
remove it. Go to step 6.
Headlamp: Reach under the
bumper and remove the rubber
cover from the back of the
headlight. Turn the collar counter-
clockwise and carefully remove
the collar and socket.
6. Remove the lamp. Apply dielectric
grease to the socket and install a
new lamp.
7. Reverse all steps to reassemble the
headlight.
Position Light
Collar
Socket
Headlamp
102
MAINTENANCE
Lights
Taillight/Brakelight Lamp Replacement
1. Open the tailgate.
2. Remove the two screws near the
tailgate latch.
3. Grasp the entire taillight assembly
and pull it away from the vehicle.
4. Remove the harness connector
from the back of the light assem-
bly.
5. Turn the lamp counterclockwise to
remove it.
6. Apply dielectric grease to the
socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
Screws
Lamp
103
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 128 for the recom-
mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. Always use POLARIS-recommended spark plugs.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 104.
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specifi-
cation.
Plug Condition Torque Specification
New Spark Plug 9-11 ft. lbs.
(12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs.
(23-27 Nm)
104
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This indi-
cates the proper type and heat range for the engine and the service.
The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect fuel.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil or incorrect throttle body adjustments.
105
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine. If it's impossible to take your vehicle to a
dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the
footrests.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying proce-
dure.
NOTICE: Serious damage can occur after immersion if fluids are not changed
promptly. See your dealer as recommended
.
7. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
8. If water has been ingested into the PVT, follow the procedure on
page 109 for drying out the PVT.
106
MAINTENANCE
Spark Arrestor
Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrestor clean-
out plug from the bottom of
the muffler.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and
release the throttle lever
several times to purge car-
bon from the system.
5. If carbon comes out of the
exhaust, cover or plug the
exhaust outlet(s). Wear
protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Place the transmission in PARK. Lock the parking brake. Repeat
steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor plug and remove the exhaust outlet cover or
plug.
WARNING
Clean-Out
Plug
107
MAINTENANCE
PVT System
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• See your dealer as outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
WARNING
108
MAINTENANCE
PVT System
The basic operation of the POLARIS PVT system is dependent on
engine speed and vehicle torque requirements. As engine speed
increases, the force exerted on the movable drive sheave by the fly-
weights also increases. This, in turn, increases the amount of pinch
applied to the drive belt. Similarly, if the engine speed decreases, the
amount of centrifugal force decreases, reducing the amount of belt
pinch.
The approximate gear ratio difference between high and low range is
1:2.25. This difference in gearing affects the operation of the PVT, espe-
cially at speeds less than 7 MPH (11 km/h), due to the system's depen-
dence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h) in
low range, the engine speed would be around 3000 RPM. This is well
above the engagement speed of 1600 - 1800 RPM. However, in high
range at 3 MPH (5 km/h), the engine would be running at only 1500
RPM. Whenever operating this close to the engagement speed, the
engine may be running at a speed too low to provide the pinch needed to
prevent belt slip. Belt slip is responsible for creating the excessive heat
that destroys belts, wears clutch components and causes outer clutch
covers to fail.
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the tempera-
ture inside the clutch cover greatly extends the life of the PVT compo-
nents (belt, cover, etc.).
109
MAINTENANCE
PVT System
When To Use Low Range and High Range
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the tempera-
ture inside the clutch cover greatly extends the life of the PVT compo-
nents (belt, cover, etc.).
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operat-
ing.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Rein-
stall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the trans-
mission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
Condition Range to Use
Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High
110
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
Your vehicle is equipped with a sealed battery, which requires little
maintenance. POLARIS does not recommend using a conventional bat-
tery in this vehicle. The orientation of the battery could result in electro-
lyte leakage, which would shorten the life of the battery considerably.
Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove corrosion with a stiff wire brush. Wash
with a solution of one tablespoon baking soda and one cup water. Rinse
well with tap water and dry off with clean shop towels. Coat the termi-
nals with dielectric grease or petroleum jelly.
Battery Removal
1. Remove the front box.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. Lift the battery out of the vehicle.
WARNING
111
MAINTENANCE
Battery
Battery Installation
Using a new battery that has not been fully charged can damage the bat-
tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 112 before installing
the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
8. Install the front box.
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 127 for the
part numbers of POLARIS products.
112
MAINTENANCE
Battery
Battery Charging
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Never pry the sealing strip off or add
any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very warm
to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufac-
turer's instructions for recharging. When using a constant current
charger, use the guidelines on the next page for recharging.
113
MAINTENANCE
Battery
Battery Charging
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
114
MAINTENANCE
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.
Throttle Cable Freeplay
1. Remove the four cover
screws from the right han-
dlebar control and remove
the cover.
2. With the handlebars
straight ahead, place very
light pressure on the throt-
tle lever. A gap of 2-3 mm
should be visible between
the throttle arm stop pin
and the throttle arm.
If adjustment is needed:
1. Locate the throttle cable
adjuster. Squeeze the end
of the rubber boot and slide
it back far enough to
expose the in-line cable
adjuster locknut.
2. Loosen the adjuster lock-
nut.
3. Rotate the boot to turn the
adjuster until 2-3 mm of
freeplay is achieved
between the stop pin and
the throttle arm. While
adjusting freeplay, flip the
throttle lever back and
forth repeatedly.
(continued on next page)
2-3 mm Gap
Throttle
Arm
Arm Stop Pin
Lock
Nut
Adjuster
Boot
Cable
Adjuster
115
MAINTENANCE
Throttle Cable Freeplay
4. Place the transmission in PARK. Lock the parking brake.
5. Start the engine and allow the idle to stabilize. If necessary, tap the
throttle lever to ensure the idle speed settles.
6. If idle speed remains above or below the recommended setting (see
specification pages), verify the correct gap. If gap is correct and idle
speed is still not satisfactory, please see your POLARIS dealer for
service.
7. With the engine running, turn the handlebars fully to the left and
right. Tap the throttle lever at each turn, verifying that idle RPM
returns to the recommended setting. If idle speed increases, it may
be necessary to increase the gap between the stop pin and throttle
arm, but do not exceed the recommended 2-3 mm gap.
8. When adjustments are complete, tighten the locknut.
9. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
10. Ensure the control cover seal is in place, then reinstall the cover and
screws.
116
MAINTENANCE
Handlebars
The handlebars can be adjusted for rider preference.
Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control and serious injury or death. Follow the adjustment
procedures exactly, or see your POLARIS dealer for service.
1. Remove the upper headlight
pod.
2. Loosen the four handlebar
bolts.
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the
gas tank or any other part of
the machine when turned fully
to the left or right.
4. Torque the front two bolts to
10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts. A
gap of up to 1/8" (3 mm) will
remain at the rear of the clamp
blocks.
Handlebar
Bolts
117
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Front and Rear Springs
The front and rear shock absorber
springs are adjusted by rotating the
adjuster either clockwise or counter-
clockwise to increase or decrease
spring tension. Accessory springs are
available through your POLARIS
dealer.
Adjuster
118
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always secure the seat in the 1-up position to prevent loss during
transporting.
5. Secure the fuel cap and oil cap.
6. Always tie the frame of the vehicle to the transporting unit securely
with suitable straps or rope. Do not attach tie straps to the front A-
arm bolt pockets.
7. Remove the key to prevent loss during transporting.
Accessories
Auxiliary power outlets provide 12-volt power for operating accesso-
ries. Accessory outlets are available for all models. POLARIS also has a
wide range of additional accessories available for your vehicle. Always
install accessories that are approved by POLARIS for your vehicle.
Please see your POLARIS dealer.
119
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its appear-
ance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a gar-
den hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
120
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the follow-
ing items:
If an informational or graphic label becomes illegible or comes off, con-
tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to
run for a while to evaporate any water that may have entered the engine
or exhaust system.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
• Wheel bearings • Electrical components
• Radiator • Switches and controls
• Transmission seals • Fuel system components
• Cab and body panels • Labels and decals
121
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 119.
Oil and Filter
Change the oil and filter. See page 78.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 71.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the recom-
mended amount. Carbon Clean removes water from fuel systems,
stabilizes fuel and removes carbon deposits from pistons, rings,
valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to
disperse through the entire fuel delivery system.
122
MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. After stabilizing the fuel, remove the spark plugs and add 2-3 table-
spoons of engine oil. To access the plug holes, use a section of clear
1/4" hose and a small plastic squeeze bottle filled with the pre-mea-
sured amount of oil.
2. Reinstall the spark plugs. Torque to specification.
3. Apply dielectric grease to the inside of each spark plug cap and rein-
stall the caps onto the plugs.
4. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protec-
tive film of fresh oil.
5. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and injectors should be completely drained of gasoline.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
96.
2. Clean the air box.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 71.
Battery Storage
See pages 111-112 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the vehicle with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent condensa-
tion, and may promote corrosion and oxidation.
123
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range during loading.
Starting out going up a
steep incline
Use low range or turn around using the K-turn (see page
60).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 109.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 109. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 48.
124
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Clogged fuel filter See your dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug(s) Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Immediately see your POLARIS dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark
plug(s)
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
Leaking exhaust components See your dealer
125
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Throttle release switch malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your dealer
Incorrect fuel Replace with recommended fuel
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
126
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Throttle release switch malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your dealer
Possible Cause Solution
Debris lodged in screen Clean the screen.
Plugged Radiator Use a garden hose to flush any debris
from the radiator fins. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.
127
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz./355 ml Aerosol)
2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL PLUS Transmission Fluid (qt./.95 l)
2878069 AGL PLUS Transmission Fluid (gal./3.8 l)
2877922 Demand Drive Plus Fluid (qt./.95 l)
2877923 Demand Drive Plus Fluid (gal./3.8 l)
2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)
2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871323 60/40 Coolant (gal./3.8 l)
2871534 60/40 Coolant (qt./.95 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, Premium All Season
2871322 Premium All Season Grease (3 oz./89 ml cartridge)
2871423 Premium All Season Grease (14 oz./414 ml cartridge)
2871460 Starter Drive Grease
2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)
2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326 Carbon Clean Plus
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
2859044 POLARIS Battery Tender™ Charger
128
SPECIFICATIONS
* Based on EU Directive 76/432/EC
**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.
Sportsman 550 X2
Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 799 lbs. (362.4 kg)
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Transmission Oil Capacity 32 oz. (948 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Rear Gearcase Oil Capacity 6.1 oz. (180 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Storage Box Capacity 400 lbs. (181 kg)
Hitch Tongue Weight 150 lbs. (68 kg) (Rear box capacity and tongue
weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 93.25 in. (237 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
82 in. (208 cm) (in TURF mode)
Engine ES550PLE
Displacement 549.7 cc
Bore x Stroke 96.6 x 75
Alternator Output 490w @ 1350 RPM/Peak 630w
Compression Ratio 9.6:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM** 1750 +/- 50
Ignition Timing 13 +/- 3 BTDC @ 1350 RPM, Engine warm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual A-Arm with 9" (22.9 cm) travel
Rear Suspension Progressive rate with 10.25" (26 cm) travel
129
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
Sportsman 550 X2
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.693:1
Drive Ratio, Front 3.818:1
Tires/Pressure, Front 26 x 8 - 14 / 7 psi (48.3 kPa)
Tires/Pressure, Rear 26 x 10 - 14 / 5 psi (34.5 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All-Wheel
Brake, Auxiliary Foot-Activated Hydraulic Disc, All-Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 2 Hi/Lo beam on bumper (55/60 watt)
Taillights 8.26 watts
Brake Light 27 watts
Instrument Cluster Digital/Analog
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
23-58
PN 1322911
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
1800-3700
(6000-12000)
23-54
PN 1322914
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
130
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH
LIMITED WARRANTY on all components of the POLARIS vehicle against defects in
material or workmanship. Warranty period will vary regionally. This warranty covers
the parts and labor charges for repair or replacement of defective parts which are cov-
ered by this warranty. This warranty begins on the date of purchase. This warranty is
transferable to another consumer during the warranty period through a POLARIS dealer.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS
will record the registration for warranty. No verification of registration will be sent to
the purchaser as the copy of the Warranty Registration Form will be the warranty entitle-
ment. If you have not signed the original registration and received the customer copy,
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE
ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-
ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
131
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
The POLARIS limited warranty excludes any failures that are not caused by a defect in
material or workmanship. This warranty does not cover accidental damage, normal wear
and tear, abuse or improper handling. This warranty also does not cover any vehicle that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, or used for purposes other than for which it was manufactured, or for any damages
which occur during trailer transit or as a result of unauthorized service or the use of
unauthorized parts. In addition, this warranty does not cover physical damage to paint or
finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in
parts, components or the vehicle due to fire, explosions or any other cause beyond
POLARIS' control.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination for which they were not designed or not intended,
including but not limited to the following items:
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps
132
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS:
LIMITATIONS OF WARRANTIES AND REMEDIES
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
• Spark Plugs • Lubricants such as oil, grease, etc.
• Filters • Batteries (unless defective)
• Fuel • Cosmetic damage/repair
• Sealants • Coolants
• Hotel fees • Meals
• Towing charges • Shipping/ handling fees
• Mileage • Product pick-up/delivery
• Rentals/Loss of product use • Loss of vacation/personal time
133
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the vehicle. The exclusive remedy for breach of this warranty
shall be, at POLARIS' exclusive option, repair or replacement of any defective materi-
als, or components or products. THE REMEDIES SET FORTH IN THIS WARRANTY
ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF
THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON
FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-
RANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PUR-
POSE. Some regions do not permit the exclusion or limitation of incidental or conse-
quential damages or implied warranties, so the above limitations or exclusions may not
apply to you if inconsistent with controlling regional law.
134
WARRANTY
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-
TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX
MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some regions do not allow lim-
itations on how long an implied warranty lasts, so the above limitation may not apply to
you if inconsistent with controlling regional law.
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS dealer autho-
rized to repair POLARIS vehicles. When requesting warranty service you must present
your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-
PORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY).
POLARIS suggests that you use your original selling dealer; however, you may use any
POLARIS Servicing Dealer to perform warranty service.
Please work with your dealer to resolve any warranty issues. Should your dealer require
any additional assistance they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which
vary by region.
If any of the above terms are void because of regional law, all other warranty terms will
remain in effect.
135
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and ser-
vices performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
136
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
137
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
138
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . . . . 22
A
Accessories . . . . . . . . . . . . . . . . . . 118
Active Descent Control Fluid . . . 84-85
Active Descent Control System. . . . 34
ADC System . . . . . . . . . . . . . . . . . . 34
Age Restrictions. . . . . . . . . . . . . . . . . 6
Air Filter . . . . . . . . . . . . . . . . . . . . . 96
All Wheel Drive System . . . . . . . 32-33
Auxiliary Foot Brake . . . . . . . . . . . . 91
B
Battery . . . . . . . . . . . . . . . . . . 110-113
Charging . . . . . . . . . . . . . 112-113
Installation . . . . . . . . . . . . . . . 111
Removal. . . . . . . . . . . . . . . . . 110
Storage . . . . . . . . . . . . . . . . . . 111
Belt Life. . . . . . . . . . . . . . . . . . . . . . 30
Boots . . . . . . . . . . . . . . . . . . . . . . . . 17
Box, Front . . . . . . . . . . . . . . . . . . . . 37
Box/Compartment, Front. . . . . . . . . 37
Brake Fluid, Auxiliary Foot Brake . 29
Brake Fluid, Main Brake System. . . 27
Brake Lever . . . . . . . . . . . . . . . . . . . 26
Brake, Foot . . . . . . . . . . . . . . . . 29, 91
Brake, Hand Lever. . . . . . . . . . . . . . 91
Brake, Parking . . . . . . . . . . . . . . . . . 28
Brakelight Lamp Replacement . . . 102
Brakes . . . . . . . . . . . . . . . . . . . . . . . 91
Break-In Period . . . . . . . . . . . . . . . . 48
C
Camber Adjustment . . . . . . . . . . . . 117
Cargo . . . . . . . . . . . . . . . . . . . . . . 67-69
Cargo Loading . . . . . . . . . . . . . . . . . 66
Caster Adjustment . . . . . . . . . . . . . 117
Check Engine Indicator . . . . . . . . . . 45
Cleaning and Storage. . . . . . . . 119-122
Clothing . . . . . . . . . . . . . . . . . . . . . . 17
Clutching . . . . . . . . . . . . . . . . . . . . 129
Cold Weather Operation . . . . . . . . . 51
Coolant Bottle . . . . . . . . . . . . . . . . . 89
Coolant, Radiator. . . . . . . . . . . . . . . 90
Cooling System . . . . . . . . . . . . . . 88-90
D
Demand Drive Fluid . . . . . . . . . . 82-83
Diagnostic Codes. . . . . . . . . . . . . . . . 47
Disengaging Active Descent Control 34
Display Units, Standard/Metric . . . . . 42
Drive Belt Wear/Burn . . . . . . . . . . . 123
Drivetrain Break-In . . . . . . . . . . . . . . 48
Driving Downhill. . . . . . . . . . . . . . . . 59
Driving in Reverse. . . . . . . . . . . . . . . 64
Driving on a Sidehill . . . . . . . . . . . . . 58
Driving on Slippery Surfaces . . . . . . 56
Driving Over Obstacles . . . . . . . . . . . 63
Driving Procedures . . . . . . . . . . . . . . 52
Driving Through Water . . . . . . . . . . . 62
Driving Uphill . . . . . . . . . . . . . . . . . . 57
Driving with a Passenger. . . . . . . 54-55
E
Electromagnetic Interference. . . . . . . 70
Engaging 4X4 . . . . . . . . . . . . . . . . . . 33
Engaging Active Descent Control . . . 34
Engine Break-In. . . . . . . . . . . . . . . . . 48
Engine Fogging . . . . . . . . . . . . . . . . 122
Engine Oil . . . . . . . . . . . . . . . . . . 76-79
Engine Stop Switch . . . . . . . . . . . . . . 23
Equipment Modifications . . . . . . . . . . 7
Error Codes, Engine . . . . . . . . . . . . . 45
European Vibration and Noise . . . . . 70
Exhaust Emission Control System . . 70
Eye Protection . . . . . . . . . . . . . . . . . . 17
F
Fluid
ADC. . . . . . . . . . . . . . . . . . . 84-85
Brake . . . . . . . . . . . . . . . . . . . . . 27
Coolant . . . . . . . . . . . . . . . . . . . 88
Demand Drive . . . . . . . . . . . 82-83
Engine Oil . . . . . . . . . . . . . . . . . 76
Rear Gearcase . . . . . . . . . . . . . . 86
Recommended Lubricants . . . . . 75
Transmission . . . . . . . . . . . . . . . 80
Fluid Change
ADC. . . . . . . . . . . . . . . . . . . . . . 85
Demand Drive . . . . . . . . . . . . . . 83
Engine Oil . . . . . . . . . . . . . . 78-79
Rear Gearcase . . . . . . . . . . . . . . 87
Transmission Oil . . . . . . . . . . . . 81
139
INDEX
F
Fluid Level
ADC . . . . . . . . . . . . . . . . . . . . . 84
Brake. . . . . . . . . . . . . . . . . . 27, 29
Coolant Bottle. . . . . . . . . . . . . . 89
Demand Drive. . . . . . . . . . . . . . 83
Engine Oil . . . . . . . . . . . . . . . . . 77
Radiator. . . . . . . . . . . . . . . . . . . 90
Rear Gearcase . . . . . . . . . . . . . . 86
Transmission Oil. . . . . . . . . . . . 80
Foot Brake, Auxiliary . . . . . . . . . . . . 29
Footwell Removal. . . . . . . . . . . . . . . 93
Front Box/Compartment . . . . . . . . . . 37
Front Gearcase (Demand Drive). 82-83
Fuel Recommendations. . . . . . . . . . . 31
Fuel Safety . . . . . . . . . . . . . . . . . . . . 15
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 31
Fuse Replacement. . . . . . . . . . . . . . . 97
G
Gasoline Handling . . . . . . . . . . . . . . 15
Gauge, Code Definitions. . . . . . . 46-47
Gauge, Digital/Analog . . . . . . . . 38-45
Gear Selector. . . . . . . . . . . . . . . . . . . 30
Gearcase Oil, Rear . . . . . . . . . . . 86-87
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 17
H
Hand Brake . . . . . . . . . . . . . . . . . . . . 91
Handlebar Adjustment . . . . . . . . . . 116
Hauling Cargo. . . . . . . . . . . . . . . 66-69
Hazard Switch. . . . . . . . . . . . . . . . . . 23
Headlight Housing Replacement . . . 99
Headlight Lamp . . . . . . . . . . . . . . . 101
Headlight Lamp Replacement . . . . 100
Headlight Switch. . . . . . . . . . . . . . . . 24
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 16
High Beam Adjustment . . . . . . . . . . 98
High Beam Switch, Momentary . . . . 23
High Range Use . . . . . . . . . . . . . . . 109
Horn Switch . . . . . . . . . . . . . . . . . . . 23
Hub Tightening . . . . . . . . . . . . . . . . . 94
I
Idle RPM Adjustment . . . . . . . . . . . 114
Immersion Maintenance . . . . . . . . . 105
Indicator Lamps . . . . . . . . . . . . . . . . 39
Instrument Cluster. . . . . . . . . . . . 38-47
K
Key Switch . . . . . . . . . . . . . . . . . . . . 22
K-Turn . . . . . . . . . . . . . . . . . . . . 60-61
L
Lights
Headlight Lamp . . . . . . . 100-101
High Beam Adjustment . . . . . . 98
Housing Replacement. . . . . . . . 99
Momentary High Beam . . . . . . 23
Position Light Lamp . . . . . . . . 101
Taillight/Brakelight. . . . . . . . . 102
Turn Signal Replacement . . . . . 99
Low Range Use. . . . . . . . . . . . . . . . 109
Lubrication Guide. . . . . . . . . . . . . . . 75
M
Maintenance Chart . . . . . . . . . . . 71-74
Master Cylinder . . . . . . . . . . . . . . . . 27
Metric Display . . . . . . . . . . . . . . . . . 42
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 25
MODE Button. . . . . . . . . . . . . . . . . . 24
Modifications . . . . . . . . . . . . . . . . . . . 7
N
Noise Emission Control System . . . . 70
O
Oil
Engine . . . . . . . . . . . . . . . . . 76-79
Rear Gearcase . . . . . . . . . . . 86-87
Transmission. . . . . . . . . . . . 80-81
Oil Change
Rear Gearcase . . . . . . . . . . . . . . 87
Transmission. . . . . . . . . . . . . . . 81
Engine . . . . . . . . . . . . . . . . . 78-79
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . 77
Rear Gearcase . . . . . . . . . . . . . . 86
Transmission. . . . . . . . . . . . . . . 80
Oil Recommendations . . . . . . . . . . . 76
Override Switch . . . . . . . . . . . . . . . . 24
140
INDEX
P
Parking Brake . . . . . . . . . . . . . . . . . 28
Parking on an Incline. . . . . . . . . . . . 65
Passenger Seat . . . . . . . . . . . . . . . 35-36
Periodic Maintenance Chart . . . . 71-74
Polaris Product List . . . . . . . . . . . . 127
Polishing the Vehicle. . . . . . . . . . . 120
Position Light Lamp . . . . . . . . . . . 101
Pre-Ride Checklist . . . . . . . . . . . . . . 49
PVT Break-In. . . . . . . . . . . . . . . . . . 48
PVT Drying . . . . . . . . . . . . . . . . . . 109
PVT System. . . . . . . . . . . . . . . 107-109
R
Reverse Operation . . . . . . . . . . . . . . 64
Rider Information Center. . . . . . . 40-45
Rider Safety . . . . . . . . . . . . . . . . . . 8-15
Riding Gear . . . . . . . . . . . . . . . . . 16-17
S
Safe Operation Practices . . . . . . . . . 50
Safety Labels . . . . . . . . . . . . . . . . 18-21
Safety Training . . . . . . . . . . . . . . . . . 6
Seat Removal . . . . . . . . . . . . . . . . . . 93
Severe Use . . . . . . . . . . . . . . . . . . . . 71
Side Panel Removal. . . . . . . . . . . . . 93
Sidehilling . . . . . . . . . . . . . . . . . . . . 58
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor . . . . . . . . . . . . . . . . 106
Spark Arrestor Requirements . . . . . 70
Spark Plug Inspection . . . . . . . 103-104
Spark Plug Recommendations. . . . 103
Spark Plugs . . . . . . . . . . . . . . . 103-104
Speedometer . . . . . . . . . . . . . . . . . . 38
Spring Adjustment, Shock . . . . . . . 117
Starting the Engine . . . . . . . . . . . . . 51
Steering Assembly. . . . . . . . . . . . . . 92
Steering Lock. . . . . . . . . . . . . . . . . . 31
Stop Switch . . . . . . . . . . . . . . . . . . . 23
Storage . . . . . . . . . . . . . . . . . . . 119-122
Storage Tips. . . . . . . . . . . . . . . 121-122
S
Switches . . . . . . . . . . . . . . . . . . . 22-24
4X4 Switch . . . . . . . . . . . . . . . . 22
Engine Stop Switch . . . . . . . . . . 23
Hazard Switch . . . . . . . . . . . . . . 23
Headlight Switch . . . . . . . . . . . . 24
Horn Switch. . . . . . . . . . . . . . . . 23
Main Key Switch. . . . . . . . . . . . 22
MODE Button . . . . . . . . . . . . . . 24
Momentary High Beam Switch . 23
Override Switch. . . . . . . . . . . . . 24
Turn Signal Switch . . . . . . . . . . 23
T
Taillight Lamp Replacement . . . . . . 102
Throttle Body Adjustment. . . . . . . . 114
Throttle Cable Freeplay Adjustment . . .
114, 115
Throttle Lever . . . . . . . . . . . . . . . . . . 25
Tires . . . . . . . . . . . . . . . . . . . . . . 94-95
Tread Depth . . . . . . . . . . . . . . . . 94
Wheel Installation . . . . . . . . . . . 95
Wheel Nut Torque . . . . . . . . . . . 95
Wheel Removal . . . . . . . . . . . . . 94
Toe Alignment. . . . . . . . . . . . . . . . . . 92
Towing Capacities . . . . . . . . . . . . . . . 68
Towing Loads . . . . . . . . . . . . . . . . . . 68
Training, Safety . . . . . . . . . . . . . . . . . . 6
Transmission . . . . . . . . . . . . . . . . . . . 30
Transmission Oil . . . . . . . . . . . . . 80-81
Transporting the Vehicle . . . . . . . . . 118
Turn Signal Switch . . . . . . . . . . . . . . 23
Turning Around on a Hill . . . . . . 60-61
Turning the Vehicle . . . . . . . . . . . . . . 53
V
Vehicle Identification Numbers. . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 105
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle . . . . . . . . 119-120
Wheel Installation . . . . . . . . . . . . . . . 95
Wheel Nut Torque Specifications . . . 95
Wheel Removal . . . . . . . . . . . . . . . . . 94
