2021
WARNING
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.
OWNER’S
MANUAL
For Maintenance and Safety
Sportsman XP 1000 S
WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road
vehicle can expose you to chemicals including engine exhaust, carbon
monoxide, phthalates, and lead, which are known to the State of California
to cause cancer and birth defects or other reproductive harm. To minimize
exposure, avoid breathing exhaust, do not idle the engine except as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
!
WARNING
Read, understand, and follow all of the instructions and safety
precautions in this manual and on all product labels.
Failure to follow the safety precautions
could result in serious injury or death.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR Code®
with your smartphone.
!
2021 Owner’s Manual
Sportsman XP 1000 S
ROHVA® is a registered trademark of Recreation Off-Highway Vehicle
Association. Loctite® is a registered trademark of Henkel Corporation.
NYOGEL® is a registered trademark of Nye Lubricants, Inc. Bluetooth® is a
registered trademark of Bluetooth Sig, Inc. QR Codes® is a registered
trademark of DENSO WAVE INCORPORATED. BatteryMinder® is a
registered trademark of VDC Electronics, Inc. MIKUNI® is a registered
trademark of MIKUNI CORPORATION. iOS® is a registered trademark of
Cisco Technologies, Inc. Android® is a registered trademark of Google LLC.
Tread Lightly® is a registered trademark of the United States Department of
Agriculture. AUTOLITE® is a registered trademark of BMO HARRIS BANK,
N.A. Duro® is a registered trademark of HWA Fong Rubber (USA) Inc. DBA
Duro Tire & Wheel Corp. BOSCH® is registered to Robert Bosch GmbH.
Unless noted, trademarks are the property of Polaris Industries, Inc.
Copyright 2020 Polaris Industries 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 discrepancies may result between the
actual vehicle and the information presented in this publication. 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.
9931371 R01
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.polaris.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. We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience
have gone into the engineering, design, and development of your POLARIS
vehicle, making it the finest machine we’ve ever produced.
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual contains
instructions for minor maintenance, but information about major repairs is
outlined in the POLARIS Service Manual and can be performed by a factory
certified Master Service Dealer (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during and after the warranty period.
For the most up-to-date owner’s manual visit https://www. polaris. com/en-us/
owners-manuals
.
3
WELCOME
Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 13
Features and Controls . . . . . . . . . . . . . . 31
Operation . . . . . . . . . . . . . . . . . . . . 59
Winch Guide. . . . . . . . . . . . . . . . . . . 79
Emission Control Systems . . . . . . . . . . . . . 89
Maintenance . . . . . . . . . . . . . . . . . . 91
Specifications . . . . . . . . . . . . . . . . . . 135
POLARIS Products . . . . . . . . . . . . . . . . 139
Troubleshooting . . . . . . . . . . . . . . . . . 141
Warranty . . . . . . . . . . . . . . . . . . . . 151
Maintenance Log . . . . . . . . . . . . . . . . 159
5
6
INTRODUCTION
IMPORTANT WARNING ABOUT THIS MANUAL
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. A POLARIS ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles,
such as motorcycles and cars. A collision or rollover can occur quickly, even
during routine maneuvers like turning, or driving on hills or over obstacles, if
you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.
• Never operate an ATV without proper instruction. Take a certified ATV safety
training course. In the United States, certified training can be found at www.
atvsafety.org
.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for
anyone under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has ready this
manual and all product labels and has completed a certified safety training
course. In the United States, certified training ca be found at www.atvsafety.
org.
7
INTRODUCTION
SAFETY SYMBOLS AND SIGNAL WORDS
The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
WARNING indicates a hazardous situation which, if not avoided, COULD result
in death or serious injury.
CAUTION
CAUTION indicates a hazardous situation which, if not avoided, COULD result
in minor to moderate injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
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.
8
INTRODUCTION
EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per EN 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
RADIO COMPLIANCE STATEMENTS
The following statements apply to radio components offered with this vehicle.
This device complies with part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference,
and (2) this device must accept any interference received, including interference
that may cause undesired operation.
This device complies with FCC RF radiation exposure limits for general
population.
This device contains license-exempt transmitter(s)/receiver(s) that comply with
Innovation, Science and Economic Development Canada’s license-exempt RSS
(s). Operation is subject to the following two conditions:
1. This device may not cause interference.
2. This device must accept any interference, including interference that may
cause undesired operation of the device.
9
INTRODUCTION
CAUTION
This equipment complies with part 15 of the Federal Communications
Commission (FCC) rules.
These requirements are intended to provide reasonable protection against
harmful interference in a residential installation. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in
accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not
occur in a particular installation.
If this equipment does cause harmful interference to radio or television
reception, which can be determined by turning the equipment off and on, the
user is encouraged to try to correct the interference by one or more of the
following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
Changes or modifications to this equipment not expressly approved by the
party responsible for compliance could void the user’s authority to operate the
equipment.
This vehicle may contain the following radio equipment or components that
contain radio equipment:
COMPONENT COMPONENT ID MANUFACTURER
B1 Gauge Bluetooth WT12 Silicon Labs
Hereby, Polaris Industries Inc. declares that the above radio equipment is in
compliance with EU Directive 2014/53/EU.
The full text of the EU declaration of conformity is available at the following
internet address:
https://www.polaris.com/en-us/radio-conformity/
10
INTRODUCTION
VEHICLE IDENTIFICATION NUMBERS
The vehicle identification number (VIN) can be found stamped on the right rear
frame tube
q
.
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
q
Engine Serial Number
w
Key Number
11
INTRODUCTION
12
SAFETY
SAFETY TRAINING
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages
you and any family members who will be riding the ATV to take a training course.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and
regulations concerning the operation of this vehicle in your area. We strongly
advise you to strictly follow the recommended maintenance program outlined in
your vehicle manual. This preventive maintenance program is designed to
ensure that all critical components on your vehicle are thoroughly inspected at
specific intervals.
SAFETY TRAINING IN THE UNITED STATES
If you purchased a new POLARIS ATV in the United States, your dealer
provided information about the authorized ATV RiderCourse
sm
that is available
to you and your eligible family members. This training is included in the
purchase price of your ATV. You were also provided with printed materials that
explain safe operating procedures. You should review this information on a
regular basis.
If you purchased a used POLARIS ATV in the United States, you can enroll in
the ATV RiderCourse
sm
for a fee. Call ATV Enrollment Express at (800) 887-
2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the
United States, please contact your dealer or local law enforcement agencies for
information about safety training.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call
the Consumer Product Safety Commission at 1-800-638-2772, or visit
www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.
SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long-
sleeve shirt, long pants, and over-the-ankle boots
at all times. Protective gear reduces the chance of
injury.
q
Helmet
w
Eye Protection
e
Long Sleeves
r
Gloves
t
Long Pants
y
Over-the-Ankle Boots
13
SAFETY
HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established
safety standards. Clasp the buckle and pull each strap tight to ensure the helmet
is properly secured to the head.
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.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding
this 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
Wear gloves for comfort and for protection from sun, cold weather and other
elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a
POLARIS vehicle with bare feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
14
SAFETY
SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s
manual for proper operating procedures.
OPERATING WITHOUT INSTRUCTION
Operating this ATV without proper instruction
increases the risk of an accident. The
operator must understand how to operate the
ATV properly in different situations and on
different types of terrain.
Beginning and inexperienced operators
should complete the recommended safety
training before operating this vehicle.
Never permit a guest to operate the ATV
unless the guest has read this manual and all
product labels and has completed a certified
safety training course.
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyone under 16
years of age.
Never allow anyone under 12 years of age to
ride as a passenger on a 2-up ATV.
Even though a child may be within the
recommended age group for operating some
ATVs, they may not have the skills, abilities,
or judgment needed to operate or ride on this
ATV safely and could be susceptible to
accident or injury.
15
SAFETY
USING ALCOHOL OR DRUGS
Never consume alcohol or drugs before or
while operating this vehicle.
Operating this vehicle after consuming
alcohol or drugs could adversely affect
operator judgment, reaction time, balance
and perception.
FAILURE TO INSPECT BEFORE OPERATING
WARNING
Failure to inspect and verify that the vehicle is in safe operating condition
before operating increases the risk of an accident.
Always perform the pre-ride inspection before each use of your vehicle to
make sure it's in safe operating condition.
Always follow the inspection and maintenance procedures and schedules
described in this owner’s manual.
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.
• Never carry fuel or other flammable liquids on this vehicle. Failure to follow
this instruction could lead to serious burn injuries or death.
• Do not smoke or allow open flames or sparks in or near the area where
refueling 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.
16
SAFETY
EXPOSURE TO EXHAUST
CAUTION
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
PROTECTIVE APPAREL
Riding in this vehicle without wearing an
approved helmet and protective eye wear
increases the risk of a serious injuries in the
event of an accident.
Always wear a helmet, eye protection,
gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
OPERATING ON PAVEMENT
This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and may
increase the risk of loss of control and accident or rollover. Avoid operating the
vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and
avoid sudden turns or stops.
OPERATING ON PUBLIC ROADS
Operating this vehicle on public streets, roads
or highways could result in a collision with
another vehicle. Never operate this vehicle
on any public street, road or highway,
including dirt and gravel roads (unless
designated for off-highway use).
17
SAFETY
OPERATING AT EXCESSIVE SPEEDS
Operating this vehicle at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate
for the terrain, the visibility and operating
conditions and your skills and experience.
PHYSICAL CONTROL OF THE VEHICLE
Removing even one hand or foot can reduce ability to control the vehicle or
could cause loss of balance and ejection from the ATV.
If a person's feet are not firmly planted on the footrests, they could come into
contact with the wheels or other moving parts and lead to accident or injury.
Always keep both hands on the handlebars and both feet on the footrests of the
ATV during operation.
TURNING IMPROPERLY
CAUTION
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
owner’s manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
18
SAFETY
JUMPS AND STUNTS
Exhibition driving increases the risk of an
accident or rollover. DO NOT do power
slides, “donuts”, jumps or other driving stunts.
Avoid exhibition driving.
IMPROPER HILL CLIMBING
Improper hill climbing could cause loss of control or rollover. Use extreme
caution when operating on hills. Always follow proper procedures for hill climbing
as described in this owner's manual. See the New Operator Driving Procedures
section for details.
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of control or rollover. Always
follow proper procedures for traveling down hills as described in this owner’s
manual. See the New Operator Driving Procedures section for details.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or rollover. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in this owner's manual. See the New Operator Driving Procedures
section for details.
19
SAFETY
STALLING WHILE CLIMBING A HILL
Stalling, rolling backwards or improperly
dismounting while climbing a hill could cause
a rollover.
• Always maintain a steady speed when
climbing a hill.
• Always engage ADC mode (if equipped)
before ascending or descending a hill. If
ADC mode is not equipped, apply AWD
mode before ascending or descending a
hill.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A passenger should also lean uphill.
• Apply the brakes.
• Lock the parking brake when fully stopped.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual.
If the ATV begins rolling downhill:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Apply the brake lever gradually.
• When fully stopped, apply the auxiliary brake as well, and then lock the
parking brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual.
20
SAFETY
OPERATING ON STEEP HILLS
Operating on excessively steep hills could
cause an overturn.
Never operate on hills too steep for the ATV
or for your abilities.
Never operate this ATV on hills steeper than
25 degrees.
OPERATING ON SLIPPERY TERRAIN
Failure to use extra caution when operating
on excessively rough, slippery or loose
terrain could cause loss of traction, loss of
control, accident or overturn.
Do not operate on excessively rough, slippery
or loose terrain until you've learned and
practiced the skills necessary to control the
vehicle on such terrain.
Always use extra caution on rough, slippery
or loose terrain.
OPERATING IN UNFAMILIAR TERRAIN
Failure to use extra caution when operating on unfamiliar terrain could result in
an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause
loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always
be alert to changing terrain conditions.
21
SAFETY
IMPROPER TIRE MAINTENANCE
Operating this vehicle with improper tires or
with improper or uneven tire pressure could
cause loss of control or accident.
Always use the size and type of tires
specified for your vehicle.
Always maintain proper tire pressure as
described in the owner's manual and on
safety labels.
OPERATING IMPROPERLY IN REVERSE
Improperly operating in reverse could result in a collision with an obstacle or
person. Always follow proper operating procedures as outlined in this manual.
See the New Operator Driving Procedures section for details.
Before shifting into reverse gear, always check for obstacles or people behind
the vehicle. When it's safe to proceed, back slowly.
OPERATING OVER OBSTACLES
Improperly operating over obstacles could
cause loss of control or rollover.
Before operating in a new area, check for
obstacles. Avoid operating over large
obstacles such as large rocks and fallen
trees. Always follow the proper procedures
outlined in this manual when operating over
obstacles. See the New Operator Driving
Procedures section for details.
22
SAFETY
SKIDDING OR SLIDING
Failure to use extra caution when operating
on excessively rough, slippery or loose
terrain could cause loss of traction, loss of
control, accident or rollover. Do not operate
on excessively slippery surfaces. Always
slow down and use additional caution when
operating on slippery surfaces.
Skidding or sliding due to loss of traction can
cause loss of control or rollover (if tires regain
traction unexpectedly). Always follow proper
procedures for operating on slippery surfaces
as described in this owner's manual. See the
New Operator Driving Procedures section for
details.
OPERATING A DAMAGED VEHICLE
CAUTION
Operating a damaged vehicle can result in an accident. After any rollover or
other accident, have a qualified service dealer inspect the entire machine for
possible damage, including (but not limited to) seat belts, rollover protection
devices, brakes, throttle, and steering systems.
OPERATING THROUGH WATER
Operating through deep or fast-flowing water can cause loss of traction, loss of
control, rollover or accident. Never operate in fast-flowing water or in water that
exceeds the floor level of the vehicle.
Always follow proper procedures for operating in water as described in this
owner’s manual.
Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will help
dry out the pads.
23
SAFETY
IMPROPER CARGO LOADING
Overloading the vehicle or carrying cargo improperly may cause changes in
stability and handling, which could cause loss of control or an accident.
• Always follow the instructions in this owner’s manual for carrying cargo.
• Never exceed the stated load capacity for this vehicle.
• Cargo should be properly distributed and securely attached.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater
distance for braking.
OPERATING ON FROZEN BODIES OF WATER
Severe injury or death can result if the vehicle and/or the operator fall through
the ice. Never operate the vehicle on a frozen body of water unless you have
first 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.
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.
POOR VISIBILITY
CAUTION
Operating this vehicle in darkness or inclement weather could result in a
collision or accident, especially if operating on a road or street. This vehicle is
not equipped with highway-approved lights. Operate this vehicle off-road only.
Use caution and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness. Clean headlights frequently and replace
burned out headlamps promptly.
PHYSICAL SKILLS
Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control.
24
SAFETY
HOT EXHAUST SYSTEMS
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system.
Use caution when traveling through tall grass, especially dry grass and when
traveling through muddy conditions. Always inspect the underside of the
vehicle and areas near the exhaust system after driving through tall grass,
weeds, brush, other tall ground cover, and muddy conditions. Promptly remove
any grass, debris or foreign matter clinging to the vehicle and pay particular
attention to the exhaust system area.
TRAILER HITCH WARNING (IF EQUIPPED)
If using a hitch, ensure the receiver does not exceed a two inch drop or raise.
WARNING
When trailering with your ATV, be aware that the exhaust is located above the
hitch ball receiver and the trailer hitch. During operation of the ATV, the
exhaust will produce hot exhaust gas that should not be inhaled and that may
elevate the surface temperature of surrounding surfaces, including trailer
surfaces (e.g., trailer hitch, trailer tongue, trailer walls, . . . etc.). To reduce the
risk of inhaling exhaust gases and to avoid risk of burn or injury, shut off your
engine and allow time for the exhaust gases to dissipate and for the surfaces
surrounding the exhaust to cool, including the trailer surfaces, before
connecting or disconnecting a trailer. To reduce the potential for the trailer hitch
or trailer tongue from getting too hot, do not use a receiver hitch with a rise of
more than two inches.
UNAUTHORIZED USE OF THE VEHICLE
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.
25
SAFETY
EQUIPMENT MODIFICATIONS
Your POLARIS vehicle is designed to provide safe operation when used as
directed. Modifications to your vehicle may negatively impact vehicle stability.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may
become less stable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds.
Do not install any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if
any non-POLARIS approved equipment and/or modifications have been added
to the vehicle that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers, or large racks, may change the handling characteristics
of the vehicle. Use only POLARIS-approved accessories, and familiarize
yourself with their function and effect on the vehicle.
The addition of certain accessories, including (but not limited to) overhead audio
speakers, may change the forward clearance in the vehicle. Polaris
recommends selecting a helmet that is compatible with the equipment on your
vehicle and provides the greatest amount of forward clearance. Always wear a
helmet that meets or exceeds the specifications in this owner’s manual. Refer to
the Safe Riding Gear section of this owner’s manual for more information. Use
only POLARIS-approved accessories.
FOR MORE INFORMATION ABOUT SAFETY IN THE UNITED STATES call
POLARIS at 1-800-342-3764.
REPORTING SAFETY DEFECTS (CANADA)
To report a safety defect to Transport Canada, you may either fill out an online
defect complaint form at their website (English: http://www/tc/gc/ca/recalls,
French: http://www.tc.gc.ca/rappels) or contact their Defect Investigations and
Recalls Division by calling toll-free 1-800-333-0510 (Canada) or 819-994-3328
(Ottawa-Gatineau area / International).
26
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, contact 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.
q
Age Warning
t
General Warning
w
Reverse Override Warning/AWD
Caution
y
“No Passenger” Warning
e
Discretionary Warning
u
Tire Pressure/Load Warning
r
Rack/Box Warning
i
Clutch Warning (Under Seat)
AGE 16 WARNING
WARNING
Operating this vehicle if you are under the age of 16 increases the chances of
severe injury or death to operator.
NEVER operate this vehicle if you are under age 16.
27
SAFETY
REVERSE OVERRIDE / AWD WARNING
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.
DISCRETIONARY WARNING
WARNING
• Never operate this ATV on HILLS steeper than 25 degrees. To prevent
overturn on hilly terrain, use throttle and brakes gradually, and shift weight
uphill.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
RACK/BOX WARNING
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 Rack Loads: Front 200 lbs. (91 kg) Rear 300 lbs. (136 kg)
28
SAFETY
GENERAL WARNING
WARNING
Improper use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE ON PUBLIC ROADS
NEVER CARRY PASSENGERS
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering and increase risk
of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough
terrain and in turns
• avoid paved surfaces - pavement may seriously affect handling and control
Locate and Read Owner's Manual. Follow All Instructions And Warnings.
NO PASSENGER WARNING
WARNING
NEVER ride as a passenger. Passengers can cause a loss of control, resulting
in SEVERE INJURY or DEATH.
29
SAFETY
TIRE PRESSURE/LOAD WARNING
WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.
• Cold tire pressure:
– Front: 10.0 psi (69 kPa)
– Rear: 10.0 psi (69 kPa)
• Maximum weight capacity: 715 lbs. (324 kg)
• Lug nut torque values: 120 ft-lbs. (163 Nm)
NEVER exceed 62 MPH (100 km/h) when rear cargo loads are above 125 lbs
(57 kg) and/or front cargo loads are above 50 lbs. (23kg).
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 250 lbs
(114 kg) and/or front cargo loads are above 100 lbs. (46 kg).
CLUTCH COVER WARNING
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.
HITCH CAPACITY LABEL
The Hitch Capacity label
o
is located on the hitch bracket.
IMPORTANT
If using a hitch, ensure the receiver does not exceed a two inch drop or raise.
TRAILER MAX WEIGHT:
1750 LBS. (794 KG) ON LEVEL
GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 175
LBS. (79 KG)
30
SAFETY
FEATURES AND CONTROLS
OVERVIEW
NOTICE
The image below is shown for reference only. Your model may vary slightly.
q
Ignition Switch
w
Engine Stop Switch
e
Mode/Reverse Override Switch
r
Headlight Switch
t
Throttle Lever
y
Driveline Switch
u
Drive Mode Switch (if equipped)
i
Auxiliary Switch (if equipped)
o
Thumb Warmer Switch (if equipped)
a
Hand Warmer Switch (if equipped)
s
Brake Lever
d
Auxiliary Outlet
f
Battery Charge Port
g
Digital Display
31
FEATURES AND CONTROLS
IGNITION SWITCH
Use the ignition switch
q
to start the engine. The key can be removed from the
switch when it is in the OFF position.
SWITCH
POSITION
FUNCTION
OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off.
RUN Turn the key the RUN position to activate electrical components. Electrical
circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter. See the
Starting the Engine section for starting procedures.
32
FEATURES AND CONTROLS
LEFT-HAND CONTROL
ENGINE STOP SWITCH
Move the stop switch
w
either left or right to the OFF position to stop the engine
quickly.
Move the stop switch to the RUN
position before attempting to start the
engine. The engine will not start or run
when the switch is off. Both the main
switch and the engine stop switch will
shut off all electrical power to the
vehicle, including lights.
MODE/REVERSE OVERRIDE SWITCH
WARNING
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.
This vehicle is equipped with a reverse speed limiter system. To gain additional
wheel speed while backing, release the throttle and press the override button
e
.
The reverse override button also acts
as a MODE button for the digital display
when held down for approximately one
half second. The override button will not
function as a MODE button if the
transmission is in reverse.
33
FEATURES AND CONTROLS
HEADLIGHT SWITCH
Use the headlight switch to turn the
lights on and off and to change the
lights from high beam to low beam. The
key must be in the ON position and the
engine stop switch must be in the RUN
position.
RIGHT-HAND CONTROL
THROTTLE LEVER
WARNING
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Immediately contact your POLARIS dealer or
other qualified person for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result
in an accident if the throttle lever sticks during operation. Always check the
lever for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform
as designed, which could result in an accident. Do not attempt to modify the
throttle control system or replace it with any after market throttle mechanisms.
Engine speed and vehicle movement
are controlled by pressing the throttle
lever
q
. The throttle lever is spring
loaded. Engine speed returns to idle
when the lever is released.
34
FEATURES AND CONTROLS
DRIVE LINE SWITCH (IF EQUIPPED)
The drive line switch
q
controls the All
Wheel Drive (AWD/4X4) system. Use
this switch to engage AWD (4X4) or
2X4. The vehicle automatically engages
4X4 when operating in reverse if the
drive mode is set to AWD (4X4).
DRIVE MODE SWITCH (IF EQUIPPED)
The Drive Mode Switch has three positions:
• Performance (PERF)
• Standard (STND)
• Work (WORK)
Always use low gear for any of the following conditions
regardless of the selected throttle control setting.
• Operating in rough terrain or over obstacles.
• Loading the vehicle onto a trailer.
• Towing heavy loads.
• Driving frequently at low RPM or at ground speeds below
7 MPH (11 km/h).
PERFORMANCE MODE
Offers a more aggressive feel to the power of the vehicle. Vehicle will accelerate
harder with less throttle movement.
WORK MODE
Throttle is smoother than standard mode. Best for when the operator wants
more precision over vehicle acceleration. This drive mode is recommended to
be used when backing up with a trailer, driving over rough terrain, or loading
vehicle on a trailer.
STANDARD MODE
Use for majority of driving.
35
FEATURES AND CONTROLS
BRAKE SYSTEM
BRAKE LEVER
WARNING
Operating the ATV with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the ATV with a spongy-feeling
brake lever. Always contact your dealer for service before operating the
vehicle.
Squeeze the brake lever
q
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
POLARIS dealer or other qualified
service facility for proper diagnosis and
repairs.
MASTER CYLINDER/BRAKE FLUID
WARNING
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.
Check the brake fluid in the master cylinder before each ride.
1. Position the ATV on a level surface.
2.
Position the handlebars so the
master cylinder
q
is level.
3. View the brake fluid level through
the indicator window
w
on the top of
the master cylinder. The eye will
appear dark when the fluid level is
full. When fluid is low, the eye will be
clear.
36
FEATURES AND CONTROLS
4. If the fluid level is low, remove the cover screws and add fluid to the fill line.
Do not overfill. Use DOT 4 brake fluid only.
5. Reinstall the cover. Torque screws to 6–8 in-lbs (0.7–0.9 Nm).
WARNING
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.
PARKING BRAKE
WARNING
Operating the ATV 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.
To lock the parking brake, do the following:
1. Place the transmission in PARK.
2.
Squeeze and release the brake
lever
q
two or three times, then
squeeze and hold.
3. Push the parking brake lock
w
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.
NOTICE
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 ATV if leaving it parked on a hill. Another option is to park the ATV in a
sidehill position. Never depend on the parking brake alone if the ATV is parked
on a hill. Always block the wheels to prevent rolling.
37
FEATURES AND CONTROLS
AUXILIARY FOOT BRAKE
WARNING
Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
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
q
.
The auxiliary foot brake is located on
the inside of the right footrest. Operate
this brake with your right foot.
If the rear wheels slide while using the
auxiliary brake, reduce brake pedal
pressure to brake the rear wheels
without skidding.
BRAKE FLUID LEVEL
Check the brake fluid level frequently for the auxiliary brake system. The
reservoir is located under the front storage box.
Maintain the fluid level between the maximum and minimum marks. Use DOT 4
brake fluid only.
FUEL CAP
This vehicle is equipped with a digital fuel gauge that will indicate a low fuel
condition. Refuel when the gauge indicates a low fuel condition.
Always refuel with the engine stopped,
and outdoors or in a well ventilated
area. Refuel on a level surface.
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.
38
FEATURES AND CONTROLS
ELECTRONIC POWER STEERING (EPS)
Electronic power steering (EPS), if equipped, engages when the ignition key is
turned to the ON position. EPS remains engaged whether the vehicle is moving
or idle. See the Instrument Cluster section for EPS Warning Indicator
information.
FRONT COMPARTMENT
q
Coolant Bottle Cap
e
Electrical/Fuse/Relay
w
Radiator Cap
r
Battery
FRONT RACK
If your model is equipped with front
compartment storage, unlock both
latches on each side and remove the
cover to gain access.
39
FEATURES AND CONTROLS
AUTOMATIC TRANSMISSION GEAR SELECTOR
The transmission gear selector
w
is located on the right side of the vehicle.
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.
NOTE
Shifting gears with the engine speed above idle or while the vehicle is moving
could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in PARK
and lock the parking brake.
TIP
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.
40
FEATURES AND CONTROLS
ALL WHEEL DRIVE SYSTEM
The All Wheel Drive system (AWD) is
controlled by the AWD momentary
switch
q
.
Engage AWD before getting into
conditions where front wheel drive may
be needed. If the rear wheels are
spinning, release the throttle before
switching to AWD.
• Push the momentary switch to the right to engage AWD mode.
• Push the momentary switch to the right twice, to engage ADC AWD mode (if
equipped).
• Push the momentary switch to the left to operate in two-wheel drive (2X4)
mode.
NOTICE
Switching to AWD or ADC AWD (if equipped) while the rear wheels are
spinning may cause severe drive shaft and gearcase damage. Always switch
to AWD or ADC AWD (if equipped) while the rear wheels have traction or are at
rest.
AWD MODE
To engage AWD mode, push the momentary switch to the right. AWD will
engage when engine speed slows to below 3100 RPM. The gauge will display
“AWD.”
There is no limit to the length of time the vehicle may remain in AWD. The
vehicle automatically engages AWD when operating in reverse if the switch is
set to the AWD position.
Once enabled, AWD remains enabled until the 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.
When in AWD, the demand drive unit will automatically engage any time the rear
wheels lose traction. When the rear wheels regain traction, the demand drive
unit will automatically disengage.
2X4 MODE
To engage 2x4 Mode, push the momentary switch to the left. AWD will
disengage when engine speed slows to below 3100 RPM. The gauge will
display “2X4.”
41
FEATURES AND CONTROLS
ADC AWD MODE (IF EQUIPPED)
To engage ADC AWD Mode, push the momentary switch to the right twice.
When the switch is on ADC AWD, the ADC system allows engine braking to all
four wheels when the vehicle descends a hill or incline. Always move the AWD
switch to ADC AWD before ascending or descending a hill.
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 following
conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 MPH (25 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 following
conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle speed exceeds 15 MPH (25 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
42
FEATURES AND CONTROLS
INSTRUMENT CLUSTER
NOTICE
Features vary by model.
Your ATV is equipped with one of three available gauge variants, (1) a standard
gauge (no Bluetooth® functionality), (2) a Bluetooth®-equipped gauge, and (3) a
no-button gauge. If your gauge is equipped with Bluetooth®, the Bluetooth®
icon will briefly display in the upper right corner of the gauge at start-up. If your
model is equipped with a no-button gauge, use the MODE button on the left
hand control to navigate the display menu.
NOTICE
The use of a high pressure washer may damage the instrument cluster. Wash
the vehicle by hand or with a garden hose using mild soap. 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.
43
FEATURES AND CONTROLS
DISPLAY AREA FUNCTION
q
Gear Indicator
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
– = Gear Signal Error (or shifter between gears)
w
Display Area 2
This area displays odometer, trip meter, trip meter 2,
voltage, engine temperature, engine hour meter,
programmable service hour interval, ground speed,
engine RPM, geofence status, or speed limit status.
Press the mode button on the left hand control to toggle
through the available options.
e
Display Area 1
This area displays engine RPM, ground speed, or
coolant temperature.
r
Fuel Gauge
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.
t
Service
Indicator
A flashing wrench symbol alerts the operator that the
preset service interval has been reached. Your POLARIS
dealer can provide scheduled maintenance. See page
56 for more information.
y
Clock (if
equipped)
The clock displays time in a 12-hour or 24-hour format.
u
AWD Indicator
Segments of the indicator illuminate based on drive
mode engaged.
44
FEATURES AND CONTROLS
INDICATOR LAMPS
INDICATOR ICON FUNCTION
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. Your authorized
POLARIS dealer can assist.
EPS Warning (if
equipped)
This indicator illuminates when a fault
has occurred in the EPS system. Your
authorized POLARIS dealer can assist.
EPS operation is possible with key on/
engine off for up to 5 minutes.
Engine Hot
This lamp illuminates to indicate an
overheated engine. If the indicator
flashes, a severe overheating condition
exists.
Neutral
This lamp illuminates when the
transmission is in neutral and the
ignition key is in the ON position.
Helmet/Seat Belt
This lamp flashes for several seconds
when the key is turned to the ON
position. The lamp is a reminder to wear
helmet and seat belt (if equipped)
before operating.
High Beam
This lamp illuminates when the
headlamp switch is set to high beam.
45
FEATURES AND CONTROLS
INDICATOR ICON FUNCTION
Chassis Fault
If applicable.
Performance
Limited
On models equipped with a low speed
limiter, indicator light will remain on
when low speed limiter is active. Lamp
illuminates when Geofencing or max
speed is enabled. Lamp remains off
when Geofencing and max speed
settings are disabled.
46
FEATURES AND CONTROLS
DISPLAY AREA 1
Pressing the MODE button
will change the information
displayed in Area 1
q
.
DISPLAY AREA 1 FUNCTION
Speed The vehicle’s speed will be displayed in mph, or km/h.
Engine
Temperature
The vehicle’s current engine temperature will be
displayed.
RPM The vehicle’s RPM will be displayed.
47
FEATURES AND CONTROLS
DISPLAY AREA 2
Toggle the Up/Down
buttons to change the
information displayed in
Area 2
w
.
DISPLAY AREA 2 FUNCTION
Odometer The vehicle’s odometer reading will be displayed.
Engine
Temperature
The vehicle Engine Temperature will be displayed.
Trip 1 The vehicle Trip 1 mileage will be displayed.
Trip 2 The vehicle Trip 2 mileage will be displayed.
RPM The vehicle RPM will be displayed.
Voltage The vehicle’s current battery voltage will be displayed.
Speed The vehicle’s current speed will be displayed.
Engine Hours The vehicle’s engine hours will be displayed.
Service Hours The vehicle’s service hours will be displayed.
48
FEATURES AND CONTROLS
OPTIONS MENU
Press and hold the MODE button to enter the Options Menu.
OPTIONS MENU NOTES
Diagnostic Codes Only displays if fault codes are
present or stored
Units - Distance Select MPH or KPH
Units - Temp Select between °F and °C
Clock Select between 12H or 24H, and set
time
Backlight Color Select between Blue or Red
Backlight Level Set backlight brightness level
Service Hours View/Set Service hours
Bluetooth® Pairing (if equipped) Pair Bluetooth® device
Exit Menu Exit
49
FEATURES AND CONTROLS
DIAGNOSTIC CODE
Diagnostic Code Screen will show available MIL that has come on during that
ignition cycle.
To access the Diagnostic Code
Screen, do the following:
1. Press and hold the MODE
button to enter the Options
Menu. “OPTIONS” will
display on the screen for 3
seconds before showing
first menu item.
2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE
button.
Toggle the Up/Down Buttons to cycle through Code(s).
NOTICE
This option will only be available if a fault code was set or is active during the
current ignition key 'on' cycle. Turning off the ignition will clear any save fault
codes from the gauge.
q
Display area 1 will show FMI
w
Display area 2 will show SPN
e
Clock Area will show Count.
50
FEATURES AND CONTROLS
NOTICE
When the gauge is displaying a fault code, the warning telltale (check engine
or EPS) will blink to indicate which controller set the fault code.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
UNIT SELECTION DISTANCE
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Units-Distance” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (MPH or KPH)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
51
FEATURES AND CONTROLS
UNIT SELECTION TEMPERATURE
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Units - Temp” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (°F or °C)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
52
FEATURES AND CONTROLS
CLOCK (IF EQUIPPED)
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Clock” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (12H or 24H)
e
With the correct unit displayed, Press the mode button which will set the
unit.
r
Toggle the Up/Down Buttons to change the units (Cycles Hours)
t
With the correct unit displayed, Press the mode button which will set the
unit.
y
Toggle the Up/Down Buttons to change the units (Cycles 10s of Minutes)
u
With the correct unit displayed, Press the mode button which will set the
unit.
i
Toggle the Up/Down Buttons to change the units (Cycles 1s of Minutes)
o
With the correct unit displayed. Press the mode button which will set the
unit and return to the Options menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
53
FEATURES AND CONTROLS
BACK LIGHT COLOR
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Backlight Color” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (Blue or Red)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
54
FEATURES AND CONTROLS
BACK LIGHT LEVEL
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Backlight Level” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (Increase or De-
crease Level)
e
With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
55
FEATURES AND CONTROLS
SERVICE HOURS
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Service Hours” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q
Press the MODE button.
w
Toggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100)
e
With the correct unit displayed, press the MODE button, which will set
the unit and return you to the Options Menu.
NOTICE
To reset service hours after they have counted down to "0.0", reselect the
existing setpoint or select a new service hour value.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
56
FEATURES AND CONTROLS
BLUETOOTH® (IF EQUIPPED)
The Bluetooth® functionality
allows users to pair their
phones with the vehicle’s
digital gauge. This function
allows users to receive call
and text alerts while
operating the vehicle.
If a text message is received
while the vehicle is moving
faster than 2 KPH, only the
sender’s name is shown
onscreen.
If you are browsing any of the Bluetooth® menus and the vehicle starts to move
faster than 2 KPH, the menu will automatically display VEHICLE MOVING. If
you attempt to access Bluetooth® menus while the vehicle is moving faster than
2 KPH, the screen will display VEHICLE MOVING momentarily, and then it will
redirect to the options menu.
PAIRING YOUR PHONE TO THE GAUGE
Use the following procedure to pair your phone with the vehicle’s digital gauge.
NOTICE
Bluetooth® functionality is compatible with both iOS® and Android® phones.
For iOS® phones, you must go to the Settings option and enable notifications.
Most Android® phones will prompt the user automatically to enable
notifications as part of the pairing process.
1. Make sure Bluetooth® is enabled on your phone.
2. Access the options menu on the vehicle’s digital gauge and select BT PAIR.
The Bluetooth® icon will begin to blink.
3. Find and select Polaris Gauge on your phone’s Bluetooth® menu or prompt.
Pairing should occur momentarily. Pairing mode will continue for up to 90
seconds or if you exit the BT PAIR menu.
After successfully pairing the phone, the vehicle’s digital gauge will automatically
reconnect with the phone each time it is powered on and within range. No further
action is required by the user at this point.
57
FEATURES AND CONTROLS
58
OPERATION
IMPORTANT INFORMATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
VEHICLE BREAK-IN PERIOD
The break-in period for your new POLARIS vehicle is the first 25 hours of
operation, or the time it takes to use the first two tanks full of gasoline. No single
action on your part is as important as a proper break-in period. Careful treatment
of a new engine and drive components will result in more efficient performance
and longer life for these components. Perform the following procedures
carefully.
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.
Use of any improper oils may cause serious engine damage. POLARIS PS-4
Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle
engine.
59
OPERATION
ENGINE AND DRIVETRAIN BREAK-IN
1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always
exercise extreme caution whenever handling gasoline.
2. Check the oil level. See the Oil Check section for reference. Add the
recommended oil as needed to maintain the oil level in the safe operating
range.
3. Drive slowly at first. Select an open area that allows room to familiarize
yourself with vehicle operation and handling.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined on the
daily pre-ride inspection checklist.
8. During the break-in period, change both the oil and the filter at 25 hours or
250 miles.
9. Check fluid levels of transmission and all gearcases after the first 25 hours of
operation and every 100 hours thereafter.
BRAKE SYSTEM BREAK-IN
Apply only moderate braking force for the first 50 stops. Aggressive or overly
forceful braking when the brake system is new could damage brake pads and
rotors.
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 during the break-in period.
If a belt fails, always clean any debris from the PVT intake and outlet duct and
from the clutch and engine compartments when replacing the belt.
60
OPERATION
PRE-RIDE CHECKLIST
Failure to inspect and verify that the ATV is in safe operating condition before
operating increases the risk of an accident. Always inspect the ATV before each
use to make sure it's in safe operating condition.
ITEM REMARKS PAGE
Brake system/lever travel Ensure proper operation
page 36
page 105
Brake fluid
Ensure proper level page 38
Auxiliary brake Ensure proper operation page 38
Front suspension Inspect, lubricate if necessary
-
Rear suspension Inspect, lubricate if necessary
-
Steering Ensure free operation
-
Tires
Inspect condition and pressure page 106
Wheels/fasteners
Inspect, ensure fastener
tightness
-
Frame nuts, bolts, fasteners
Inspect, ensure tightness
-
Fuel and oil
Ensure proper levels page 97
Coolant level
Ensure proper level page 103
Coolant hoses
Inspect for leaks
-
Throttle
Ensure proper operation page 34
Indicator lights/switches Ensure operation page 45
Engine stop switch Ensure proper operation page 33
Air filter, pre-filter Inspect, clean page 109
Headlamp Check operation page 31
Brake light/taillight Check operation
-
Riding gear
Wear approved helmet,
goggles, and protective
clothing
page 13
61
OPERATION
ITEM REMARKS PAGE
Winch (if equipped) Inspect cable and switch page 79
Grass and leaves Remove grass, leaves, foreign
matter, and other flammable
material or debris, especially
near the exhaust system.
-
SAFE OPERATION PRACTICES
1. Complete the recommended safety training before operating this vehicle.
Visit www.atvsafety.org for safety courses and riding tips. See page 13 for
details.
2. Do not allow anyone under 16 years of age to operate this vehicle. Do not
allow anyone with cognitive or physical disabilities to operate this vehicle.
3. Never carry a passenger on a 1-up ATV. Never carry more than one
passenger on a 2-up ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in
an enclosed area.
5. Before operating, learn how to use the auxiliary brake for emergency
situations (if service brakes become inoperable).
6. Operate this vehicle off-road only. Never operate the vehicle on pavement or
on any public street, road or highway, including dirt and gravel roads.
7. Use caution and drive at reduced speeds in conditions of reduced visibility
such as fog, rain and darkness. Clean headlights frequently and replace
burned out headlamps promptly.
8. 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.
9. Never consume alcohol or drugs before or while operating an ATV.
10. Always use the size and type of tires specified for your vehicle. Always
maintain proper tire pressure.
11. Never operate a damaged ATV. After any overturn or accident, have a
qualified service dealer inspect the entire machine for possible damage.
12. Never operate the ATV 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 ATV, you and your cargo, together with any other
vehicles in your party.
62
OPERATION
13. Do not touch hot exhaust system components. Always keep combustible
materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to prevent
unauthorized use.
TRAIL ETIQUETTE
Always practice good etiquette when riding. Allow a safe distance between your
vehicle and other vehicles operating in the same area. Communicate to
oncoming operators by signaling the number of vehicles in your group. When
stopping, move your vehicle to the edge of the trail as far as possible to allow
others to pass safely.
KNOW YOUR RIDING AREA/TREAD LIGHTLY!®
Familiarize yourself with all laws and regulations concerning the operation of this
vehicle in your area. Respect the environment in which you ride your vehicle.
Find out where the designated riding areas are by contacting your POLARIS
dealer, a local riding club, or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast,
you represent the sport and can set a good example (or a poor example) for
others to follow. Tread lightly!® Operate with respect for the terrain, avoid
littering, and always stay on the designated trails.
STARTING THE ENGINE
1. Position the vehicle on a level surface outdoors or in a well- ventilated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Sit on the vehicle and move the engine stop switch to RUN.
NOTICE
Do not press the throttle while starting the engine.
5. Turn the ignition key past the 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.
63
OPERATION
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 accumulation increases as outside
temperature decreases.
DRIVING PROCEDURES
NEW OPERATOR DRIVING PROCEDURES
1. Wear protective riding gear. See the Safe Riding Gear section.
2. Perform the pre-ride inspection.
3. Place the transmission
in PARK.
4. Lock the brake holding
latch.
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 brake holding latch.
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.
64
OPERATION
TURNING THE VEHICLE
Both rear wheels drive equally at all times. This means that the outside wheel
must travel a greater distance than the inside wheel when turning, and the inside
tire must slip traction slightly.
1. Slow down.
2. Never turn quickly when carrying cargo.
3. Steer in the direction of the turn.
4. Keep both feet on the footrests.
5. Lean your upper body to the inside of the turn while supporting your weight
on the outer footrest. This technique alters the balance of traction between
the rear wheels, allowing the turn to be made smoothly. The same leaning
technique should be used for turning in reverse.
6. Practice making turns at slow speeds before attempting to turn at faster
speeds.
WARNING
Turning improperly can result in vehicle overturn. Never turn abruptly or at
sharp angles. Never turn at high speeds.
65
OPERATION
DRIVING ON SLIPPERY SURFACES
WARNING
Skidding or sliding can cause loss of control or rollover (if tires regain traction
unexpectedly). When operating on slippery surfaces such as ice or loose
gravel, reduce speed and use extra caution to reduce the chance of skidding or
sliding out of control. Do not operate on excessively slippery surfaces.
Whenever riding on slippery surfaces such as wet trails or loose gravel, or
during freezing weather, 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. Maintain a high level of alertness, reading the trail and avoiding quick, sharp
turns, which can cause skids.
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.
66
OPERATION
DRIVING UPHILL
Braking and handling are greatly affected when operating in hilly terrain.
Improper procedure could cause loss of control or overturn. Whenever traveling
uphill, follow these precautions:
1. Always engage ADC before ascending or descending a hill.
2. Drive straight uphill.
3. Avoid steep hills. Maximum incline is: 25°
4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with excessively slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill.
8. Proceed at a steady rate of speed and throttle opening. Opening the throttle
suddenly could cause the ATV to flip over backwards.
9. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or
another vehicle or person could be on the other side of the hill.
10. Remain alert and be prepared to take emergency action. This may include
quick dismounting of the vehicle.
67
OPERATION
DRIVING DOWNHILL
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Always engage ADC mode before ascending or descending a hill.
3. Avoid steep hills. Maximum incline is 25°
4. Always descend a hill with the transmission in forward gear. Do not descend
a hill with the transmission in neutral.
5. Slow down. Never travel down a hill at high speed.
6. Drive straight downhill. Avoid traveling down a hill at an angle, which would
cause the vehicle to lean sharply to one side.
7. Shift body weight uphill.
8. 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.
68
OPERATION
DRIVING ON A SIDEHILL (SIDEHILLING)
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or overturn. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a sidehill is unavoidable
, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
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!
69
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.
1. Stop and lock the parking brake while keeping body weight uphill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a
hill. See the Switch Location section for details.
3. Leave the transmission in forward and shut off the engine.
4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill.
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 pointing across the hill or
slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side, keeping
body weight uphill. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed slowly, controlling speed with the
brake lever, until the vehicle is on more level ground.
70
OPERATION
DRIVING THROUGH WATER
NOTICE
Major engine damage can result if the vehicle is not thoroughly inspected after
operation in water. Perform the services outlined in the Periodic Maintenance
Chart. 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, service is required before starting the engine. Your
POLARIS dealer can provide this service. If it's impossible to bring the vehicle
in before starting the engine, perform the service outlined in the Vehicle
Immersion section of this manual, and take the vehicle in for service at the first
opportunity.
Your ATV can operate through water with a maximum recommended depth
equal to the bottom of the footrests.
Follow these procedures
when operating through
water:
1. Determine water
depths and current
before entering water.
2. Choose a crossing
where both banks have
gradual inclines.
3. Avoid operating
through deep or fast-
flowing water.
4. After leaving water, test the brakes. Apply them lightly several times while
driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not
make sudden throttle changes.
71
OPERATION
DRIVING OVER OBSTACLES
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards
such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not
all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
5. Always have a passenger dismount before operating over an obstacle that
could cause a fall from the vehicle or vehicle tipover.
72
OPERATION
DRIVING IN REVERSE
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is required for
vehicle movement. Use the override with caution as rearward vehicle speed
is greatly increased. Do not operate at wide open throttle. Operate the
throttle just enough to maintain a desired speed.
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.
73
OPERATION
STOPPING THE VEHICLE
1. Release the throttle completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
WARNING
A rolling vehicle can cause serious injury. Always place the transmission in
PARK before stopping the engine.
BRAKING
1. Release the throttle completely.
CAUTION
When the throttle is released completely and engine speed slows to near idle,
the vehicle has no engine braking.
2. Apply the brakes evenly and firmly. Practice starting and stopping (using the
brakes) until you're familiar with the controls.
PARKING THE VEHICLE
1. Stop the vehicle on a level surface. When parking inside a garage or other
structure, be sure that the structure is well ventilated and that the vehicle is
not close to any source of flame or sparks, including any appliance with pilot
lights.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Engage the parking brake (if equipped).
5. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
6. Remove the ignition key to prevent unauthorized use.
74
OPERATION
HAULING CARGO
CARGO WARNING
WARNING
Overloading the vehicle or carrying or towing cargo improperly can alter
vehicle handling and may cause loss of control or brake instability, which can
result in serious injury or death. Always follow these precautions when hauling
cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, 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.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads
high on the racks raises the center of gravity of the vehicle and creates a less
stable operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the
vehicle.
WARNING
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the
rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
The vehicle should never exceed 10 mph (16 kph) while towing a load on a
level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing
loads in rough terrain, while cornering, or while ascending or descending a hill.
76
OPERATION
HAULING CARGO GUIDELINES
1. Never exceed the weight capacities specified for your ATV on warning labels
and in the specifications section of this manual
2. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on
the rear rack) and mounted as low as possible.
3. When operating over rough or hilly terrain, reduce speed and cargo weight to
maintain stable driving conditions.
4. NEVER exceed 62 MPH (100 km/h) when rear cargo loads are above 125
lbs (57 kg) and/or front cargo loads are above 50 lbs. (23kg). NEVER exceed
50 MPH (80 km/h) when rear cargo loads are above 250 lbs (114 kg) and/or
front cargo loads are above 100 lbs. (46 kg).
5. Do not obstruct the headlight beam with cargo.
6. Slow down.
7. Use low forward gear when hauling or towing heavy cargo to extend belt life.
8. Always operate the vehicle with extreme caution whenever hauling or towing
loads. Balance, handling and control may be affected.
TOWING LOADS
Always attach a towed load to the hitch point. Remove the hitch from the ATV
when not towing a trailer. If towing a load, reduce rear rack cargo weight by the
amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must not
exceed the rear rack capacity.
• The total load (operator, 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 ATV warranty.
Never install a hitch longer than 4" (10 cm). Never install automotive
accessories on your POLARIS ATV. Always install POLARIS-approved (or
equivalent) accessories designed for ATV use.
77
OPERATION
WINCH GUIDE
WINCH SAFETY
These safety warnings and instructions apply if your vehicle came equipped with
a winch or if you choose to add an accessory winch to your vehicle.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed
synthetic rope. The term “winch cable” will be used for either unless noted
otherwise.
WINCH SAFETY PRECAUTIONS
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the winch.
5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead
and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving vehicle.
See the Shock Loading section on page 87.
7. Always keep the area around the vehicle, winch, winch cable, and load clear
of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not
being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped
around the winch drum at all times. The friction provided by this wrapped
cable allows the drum to pull on the winch cable and move the load.
10. Always apply your vehicle’s park brake and/or park mechanism to hold the
vehicle in place during winching. Use wheel chocks if needed.
11. Always align the vehicle and winch with the load directly in front of the
vehicle as much as possible. Avoid winching with the winch cable at an angle
to the winching vehicle’s centerline whenever possible.
79
WINCH GUIDE
12. If winching at an angle is unavoidable, follow these precautions:
a. Look at the winch drum occasionally. Never let the winch cable “stack” or
accumulate at one end of the winch drum. Too much winch cable at one
end of the winch drum can damage the winch and the winch cable.
b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to
feed and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the winching
vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s rated
capacity.
15. The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the
winch cable while winching a load.
17. Never let the winch cable run through
your hands, even if wearing heavy gloves.
18. Never release the clutch on the winch
when the winch cable is under load.
19. Never use the winch for lifting or
transporting people.
20. Never use the winch to hoist or suspend a
vertical load.
21. Always inspect your winch and winch cable before each use.
22. Never winch the hook fully into the winch. This can cause damage to winch
components.
23. Unplug the remote control from the vehicle when the winch is not in use to
prevent inadvertent activation and use by unauthorized persons.
24. Never grease or oil the winch cable. This will cause the winch cable to collect
debris that will shorten the life of the cable.
80
WINCH GUIDE
WINCH OPERATION
Read the Winch Safety Precautions in the preceding pages before using your
winch.
TIP
Consider practicing the operation and use of your winch before you actually
need to use it in the field.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to
deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any
signs of damage or parts in need of repair or replacement before each use.
Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch
is being used (or has been used) for lifting an accessory plow assembly.
Promptly replace any worn or damaged cable.
2. Never operate a winch or a vehicle in
need of repair or service.
3. Always apply your vehicle’s park brake
and/ or park mechanism to hold the
vehicle in place during winching. Use
wheel chocks if needed.
4. Always use the hook strap when handling
the hook.
81
WINCH GUIDE
WARNING
Never put your fingers into the hook. This could lead to SEVERE INJURY.
• Attach the hook itself onto the load or use a tow strap or chain to secure the
load to the winch cable.
TIP
A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
WARNING
Never use a recovery strap when winching due to the excessive energy that
can be released if the winch cable breaks. This can result in SEVERE INJURY
or DEATH. See the Shock Loading section on page 87.
• Never hook the winch cable back onto itself. This will damage the winch cable
and may result in winch cable failure.
WARNING
Replace the winch cable at the first sign of damage to prevent SEVERE
INJURY or DEATH in the event of failure. For your safety, always replace
POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer, or other
qualified dealer.
82
WINCH GUIDE
• If possible, keep the winch cable aligned with the centerline of the winching
vehicle. This will help the spooling of the winch cable and reduce the load on
the fairlead.
• If freeing a stuck vehicle by attaching to a tree, use an item such as a tow
strap to avoid damaging the tree during winch operation. Sharp cables and
chains can damage and even kill trees. Please remember to TreadLightly®
(treadlightly.org).
• Before operating the winch, be sure that the safety latch on the winch cable
hook is fully seated when the load is attached.
• Never operate your winch with a damaged hook or latch. Always replace
damaged parts before using the winch.
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’s pulling
capacity. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided by this
wrapped cable allows the drum to pull on the winch cable and move the load.
8. Read and adhere to the following information for winch damping to ensure
safe winch use.
a. In order to absorb energy that could be released by a winch cable failure,
always place a “damper” on the winch cable. A damper can be heavy
jacket, tarp, or other soft, dense object. A damper can absorb much of the
energy released if a winch cable breaks when winching. Even a tree limb
can help as a damper if no other items are available to you.
b. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
83
WINCH GUIDE
c. On a long pull, it may be necessary to stop winching so that the damper
can be repositioned to the new mid-point of the winch cable. Always
release the tension on the winch cable before repositioning the damper.
d. Avoid being directly in line with the winch cable whenever possible. Also,
never permit others to stand near or in line with the winch cable during
winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
11. The ONLY time a winch-equipped vehicle should be moving when using the
winch is when that vehicle itself is stuck. The winch equipped vehicle should
NEVER be in motion to “shock” load the winch cable in an attempt to move a
second stuck vehicle. See the Shock Loading section on page 87. For your
safety, always follow these guidelines when winching a vehicle free:
a. Release the winch clutch and spool out the necessary length of winch
cable.
b. Align the winch cable as close as possible to the winching vehicle’s
centerline.
c. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual.
d. Re-engage the clutch on the winch.
e. Slowly winch in the slack in the winch cable.
f. Select the proper vehicle gear to propel the stuck vehicle in the direction
of winching.
g. Shift to the lowest gear available on the stuck vehicle.
h. Slowly and carefully apply vehicle throttle and winch together to free the
vehicle.
i. Stop winching as soon as the stuck vehicle is able to propel itself without
the help of the winch.
j. Detach the winch cable hook.
k. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the winch cable to
a suspension component, brush guard, bumper or cargo rack. Vehicle
damage may result. Instead, attach the winch to a strong portion of the
vehicle frame or hitch.
84
WINCH GUIDE
13. Extensive winching will run down the battery on the winching vehicle. Let the
winching vehicle’s engine run while operating the winch to prevent the
battery from running low if winching for long periods.
14. The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
15. After winching is complete, especially if winching at an angle, it may be
necessary to re-distribute the winch cable across the winch drum. You will
need an assistant to perform this task.
a. Release the clutch on the winch.
b. Feed out the winch cable that is unevenly bunched up in one area.
c. Re-engage the winch clutch.
d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg)
of tension using the hook strap.
e. Slowly winch the cable in while your assistant moves the end of the winch
cable back and forth horizontally to evenly distribute the winch cable on
the drum.
f. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
85
WINCH GUIDE
WINCH CABLE CARE
WARNING
Use of worn or damaged cable could lead to sudden failure and SEVERE
INJURY.
For your safety, always replace POLARIS winch parts (including the cable) with
genuine POLARIS replacement parts available at your authorized POLARIS
dealer, or other qualified person.
1. Always inspect your winch before each use. Inspect for worn or loose parts
including mounting hardware. Never use the winch if any part needs repair or
replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked
winch cable.
A kinked winch cable made of wire rope
is shown at right. Even after being
“straightened out,” this cable has
already been permanently and severely
damaged. Promptly discontinue use of
a winch cable in this condition.
A kinked winch cable made of wire rope
that has been “straightened out” is
shown at right. Even though it may look
usable, the cable has been permanently
and severely damaged. It can no longer
transmit the load that it could prior to
kinking. Promptly discontinue use of a
winch cable in this condition.
A winch cable made of synthetic rope
should be inspected for signs of fraying.
Replace the cable if fraying is observed
(shown below). Promptly discontinue
use of a winch cable in this condition.
Also replace the winch cable if there are
fused or melted fibers. Such an area of
the synthetic rope will be stiff and
appear smooth or glazed. Promptly
discontinue use of a winch cable in this
condition.
86
WINCH GUIDE
SHOCK LOADING
WARNING
Your winch cable is very strong but it is NOT designed for dynamic, or “shock”
loading. Shock loading may tension a winch cable beyond its strength and
cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope
and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up
slack in the winch cable by moving the winching vehicle in an attempt to
move an object. This is a dangerous practice. It generates high winch cable
loads that may exceed the strength of the cable. Even a slowly moving
vehicle can create large shock loads in a winch cable.
WARNING
SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts
extra load on the winch, winch cable, and generates excessive heat from the
motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an object with a
winch produces shock loading of the cable even when towing at slow
speeds. Towing from a winch also positions the towing force high on the
vehicle. This can cause instability of the vehicle and possibly lead to an
accident.
4. Never use recovery straps with your winch. Recovery straps are designed to
stretch and can store energy. This stored energy in the recovery strap is
released if a winch cable fails making the event even more hazardous.
Similarly, never use elastic “bungie” cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation
vehicle. This type of use also causes shock loading that can cause damage
to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced
by the winch motor when operated from a stationary vehicle. Always
remember that the winch and winch cable are NOT designed for shock
loading.
87
WINCH GUIDE
WINCH MAINTENANCE AND SERVICE SAFETY
WARNING
Improper or lack of winch maintenance and service could lead to SEVERE
INJURY or DEATH. Always follow all winch instructions and warnings in this
manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch
cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections
to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable)
with genuine POLARIS replacement parts available at your authorized
POLARIS dealer, or other qualified person.
5. Some winch models use wire rope as the winch cable. Other winches use a
specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer
rope such as can be purchased in a hardware store. Although they may look
similar, they are NOT alike. A polymer rope not designed for winch use will
stretch and store excessive energy when winching.
WARNING
Failure of a stretched rope under winching conditions will release all of the
stored energy. This will increase the chances of SEVERE INJURY or DEATH.
88
WINCH GUIDE
EMISSION CONTROL SYSTEMS
NOISE EMISSION CONTROL SYSTEM
Do not modify the engine, intake or exhaust components, as doing so may affect
compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local
noise level requirements.
OPERATION ON PUBLIC LANDS IN THE U.S.A.
Your vehicle has a spark arrester that was tested and qualified to be in
accordance with the USFS standard 5100-1C. Federal law requires that this
spark arrester be installed and functional when the vehicle is operated on public
lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43
CFR 420. Violations are subject to monetary penalties. Federal regulations can
be viewed online at www.gpoaccess.gov/ecfr/.
CRANKCASE EMISSION CONTROL SYSTEM
This engine is equipped with a closed crankcase system. Blow-by gases are
forced back to the combustion chamber by the intake system. All exhaust gases
exit through the exhaust system.
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.
The emissions label is located on the right front frame of the vehicle.
ELECTROMAGNETIC INTERFERENCE
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of UN ECE Regulation 10.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy.
People with active or non-active implantable medical devices (such as heart
monitoring or controlling devices) should review the limitations of their device
and the applicable electromagnetic standards and directives that apply to this
vehicle.
89
EMISSION CONTROL SYSTEMS
90
MAINTENANCE
PERIODIC MAINTENANCE
Any qualified repair shop or person may maintain, replace or repair the emission
control devices or systems on your vehicle. An authorized POLARIS dealer can
perform any service that may be necessary for your vehicle. POLARIS also
recommends POLARIS parts for emissions-related service, however equivalent
parts can be used.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket
parts manufacturer reduces the effectiveness of the vehicle’s emission controls.
Tampering with emission controls is prohibited by federal law.
Owners are responsible for performing the scheduled maintenance identified in
this owner’s manual. Careful periodic maintenance will help keep your vehicle in
safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for replacement parts, genuine
POLARIS parts are available from your POLARIS dealer. Equivalent parts may
be used for emissions-related service.
Record maintenance and service in the Maintenance Log beginning on page
159. Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, a qualified
dealer can perform these operations. Maintenance intervals in the following
chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be
inspected and serviced more frequently.
91
MAINTENANCE
SEVERE USE DEFINITION
• Frequent immersion in mud, water or sand
• Frequent or prolonged operation in dusty environments
• Short trip cold weather operation
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
Pay special attention to the oil level. A rise in oil level during cold weather can
indicate contaminants collecting in the oil sump or crankcase. 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. Your dealer can assist.
MAINTENANCE CHART KEY
SYMBOL DESCRIPTION
XU Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized Polaris dealer or other qualified person perform these services.
WARNING
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 or other qualified person perform these services.
Perform all services at whichever maintenance interval is reached first. Record
maintenance and service in the Maintenance Log.
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
Steering
Pre-Ride
Inspect and make adjustments as
needed.
Front Suspension
Rear Suspension
Tires
Brake Fluid Level
Brake Lever Travel
Brake System
Wheels / Fasteners
CV Boot
92
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
Frame Fasteners
Engine Oil Level
Winch (if equipped)
XU
Air Filter (Pre-
Filter)
-
Daily
-
Inspect; clean often; replace as
needed
Air Box Sediment
Tube
-
Daily
-
Drain deposits when visible
Coolant -
Daily
-
Check level daily, change coolant
every two years
Head Lights / Tail
Lights
-
Daily
-
Check operation; apply dielectric
grease if replacing
Power Steering
unit
(If equipped)
-
Daily Inspect daily, clean often
XU
Air Filter (main
element)
-
Weekly
-
Inspect; replace as needed
XU
D
Brake Pad Wear 10 H
Monthly
100
(160)
Inspect periodically
Battery
20 H
Monthly
200
(320)
Check terminals; clean; test
Fuel System
20 H
Monthly
-
Turn key on to pressurize fuel pump,
check lines/fittings for leaks and
abrasion.
XU
Engine Oil Change
25 H 1 M -
Break-in oil and filter change
XU
Demand Drive
Fluid
25 H 1 M
250
(400)
Break-in fluid level check
XU Rear Gearcase Oil 25 H 1 M
250
(400)
Break-in fluid level check
XU Transmission Fluid 25 H 1 M
250
(400)
Break-in fluid level check
XU
General
Lubrication
50 H 3 M
500
(800)
Lubricate all fittings, pivots, cables,
etc.
Shift Linkage
50 H 3 M
500
(800)
Inspect
D
Steering
50 H 6 M
500
(800)
Lubricate
XU
Front/Rear
Suspension
50 H 6 M
500
(800)
Lubricate
XU
Throttle Release
Switch
50 H 6 M
500
(800)
Inspect; adjust; lubricate; replace if
necessary
Throttle Body
Intake Duct
50 H 6 M
500
(800)
Inspect ducts for proper sealing / air
leaks
93
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
Drive Belt 50 H 6 M
500
(800)
Inspect ducts for proper sealing / air
leaks
Cooling System
50 H 6 M
1000
(1600)
Inspect coolant strength seasonally;
pressure test system yearly
XU Radiator 50 H 6 M
1000
(1600)
Inspect; clean external surfaces
XU
Cooling Hoses
50 H 6 M
1000
(1600)
Inspect for leaks
XU
Oil lines and
fasteners
100 H 6 M
1000
(1600)
Inspect for leaks and loose fittings
XU
Engine oil change
100 H 6 M
1000
(1600)
Change the oil and filter
XU
Demand drive fluid
(normal use)
100 H 12 M
600
(1000)
Change fluid
XU
Rear gearcase oil
100 H 12 M
600
(1000)
Change fluid
XU Transmission oil 100 H 12 M
600
(1000)
Change fluid
D
Fuel System
100 H 12 M
600
(1000)
Cycle key to pressurize fuel pump;
check for leaks at fill cap, fuel lines/
rail and fuel pump
XU
Engine Mounts
100 H 12 M
1000
(1600)
Inspect
Exhaust Pipe /
Silencer
100 H 12 M
1000
(1600)
Inspect
XU
Spark Plug
100 H 12 M
600
(1000)
Inspect; replace as needed
XU
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/
Driven)
100 H 12 M
1000
(1600)
Inspect; clean; replace worn parts
D
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
Spark Arrestor
300 H 36 M
3000
(4800)
Clean out; or remove clean out plug
XU Coolant - 60 M -
Replace coolant (50/50 Extended Life
Coolant)
XU Valve Clearance 500 H -
5000
(8000)
Inspect; adjust as needed
94
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
D
Toe Adjustment
-
Inspect periodically; adjust as needed
Headlight Aim
-
Adjust as needed
LUBRICATION GUIDE
Check and lubricate all components at the intervals outlined in the Periodic
Maintenance Chart. 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 RECOM-
MENDED
LUBRICANT
CAPACITY
AT FLUID
CHANGE
FILL PLUG
TORQUE
DRAIN
PLUG
TORQUE
SEE PAGE
Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
— 12 ft-lbs
(16 Nm)
page 96
Transmission
Oil
AGL
Gearcase
Lubricant &
Transmission
Fluid
37 oz.
(1100 ml)
10-14 ft-lbs
(14-19 Nm)
10-14 ft-lbs
(14-19 Nm)
page 100
Demand
Drive Fluid
(Front
Gearcase)
Demand
Drive Fluid
9.3 oz. (275
ml)
8-10 ft-lbs
(11-14 Nm)
11 ft-lbs
(15 Nm)
page 101
Rear
Gearcase Oil
ATV Angle
Drive Fluid
(or GL5 80-
90 weight
gear lube)
7.1 oz. (210
ml)
10-14 ft-lbs
(14-19 Nm)
10-14 ft-lbs
(14-19 Nm)
page 102
Brake Fluid DOT 4 Brake
Fluid
— — — page 38
Front Prop
Shaft Yoke
U-Joint
Grease
Grease fittings (3 pumps maximum) every 500 miles, before long
periods of storage, or after pressure washing or submerging.
95
MAINTENANCE
ENGINE OIL
Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart. Always use the recommended engine oil. Always change
the oil filter whenever changing oil.
Pay special attention to the oil level. A rise in oil level during cold weather can
indicate contaminants collecting in the oil sump or crankcase. 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. Your dealer can assist.
WARNING
Vehicle operation with insufficient, deteriorated, or contaminated engine oil will
cause accelerated wear and may result in engine seizure, accident and injury.
Always perform the maintenance procedures as outlined in the Periodic
Maintenance Chart.
OIL RECOMMENDATIONS
Always change the oil filter whenever changing oil.
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle
oil or a similar oil for this engine. Oil may need to be changed more frequently if
POLARIS oil is not used. Always use 5W-50 oil. Follow the manufacturer's
recommendations for ambient temperature operation.
See the Lubrication Guide section for fluid recommendations, capacities and
plug torques.
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.
96
MAINTENANCE
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 ATV
q
. 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.
97
MAINTENANCE
OIL AND FILTER CHANGE
See the fluid recommendation table for capacities and plug torques. Always
change the oil and filter at the intervals outlined in the Periodic Maintenance
Chart beginning on page 92. 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 minutes.
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.
CAUTION
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.
9. Remove the oil filter cover plate by loosening the three screws holding into
place.
10. Place shop towels beneath the oil filter. Using an oil filter wrench (available
from your POLARIS dealer), turn the filter counter- clockwise to remove it.
98
MAINTENANCE
11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
12. 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.
13. Install the new filter and rotate it clockwise by hand until the filter gasket
contacts the sealing surface, then turn it an additional 1/2 turn.
14. Remove the dipstick. Add the proper amount of the recommended oil. Do not
overfill.
15. Reinstall the dipstick.
16. Place the transmission in PARK.
17. Lock the parking brake.
18. Start the engine. Allow it to idle for one to two minutes.
19. Stop the engine.
20. Check for leaks.
21. Check the oil level. Add oil as needed to bring the level to the upper mark on
the dipstick.
22. Dispose of used filter and oil properly.
99
MAINTENANCE
TRANSMISSION OIL
Always check and change the
transmission oil at the intervals
outlined in the Periodic Maintenance
Chart. See the Fluid Recommendation
table for capacities and plug torques.
Maintain the oil level at the bottom of
the fill plug hole
w
. The fill plug is
located on the right side of the ATV
behind the footwell. The drain plug
q
is located on the bottom rear side of
the gearcase.
OIL CHECK
1. Remove the fill plug. Check the oil level.
2. Add the recommended fluid as needed to bring the level to the bottom of the
fill hole threads.
3. Reinstall the fill plug. Torque to specification.
4. Reinstall the footwell.
OIL CHANGE
1. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil
to drain completely.
2. Clean and reinstall the drain plug. Torque to specification.
3. Remove the fill plug. Add the proper amount of the recommended oil.
4. Reinstall the fill plug. Torque to specification.
5. Check for leaks.
6. Reinstall the footwell.
7. Dispose of used oil properly.
100
MAINTENANCE
FRONT GEARCASE (DEMAND DRIVE) FLUID
Always check and change the demand drive fluid at the intervals outlined in the
Periodic Maintenance Chart.
Change the front gearcase fluid every 25 hours if the ADC unit is exposed to
extreme use. Extreme use includes any of the following:
• 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
TIP
If the front gearcase is making excessive noise during ADC operation, change
the demand drive fluid. If the noise continues, please see your POLARIS
dealer or other qualified service facility for service.
Use the recommended fluid. Use of other fluids may result in improper operation
of components. Maintain the fluid level at the bottom of the fill hole threads. 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.
FLUID CHECK
1. Position the vehicle on a level
surface. Remove the fill plug
q
.
Check the fluid level.
2. Add the recommended fluid as
needed to bring the level to the
bottom 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
w
.
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.
101
MAINTENANCE
REAR GEARCASE OIL
Always check and change the rear gearcase oil at the intervals outlined in the
Periodic Maintenance Chart. See page 139 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
q
. 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.
OIL CHANGE
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole
w
.
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.
102
MAINTENANCE
POWER STEERING UNIT (IF EQUIPPED)
If your model is equipped with
power steering, frequently clean the
areas around and on the power
steering unit to allow proper cooling.
Clean these areas
e
thoroughly.
STEERING ASSEMBLY
The steering assembly of the ATV should be checked periodically for loose nuts
and bolts. If loose nuts and bolts are found, see your authorized dealer or other
qualified service facility before operating the vehicle.
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 contracting (cooled)
coolant is drawn back up from the bottle, past the pressure 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 Antifreeze 50/50 Premix. This
antifreeze is already premixed and ready to use. Do not dilute with water. See
the Polaris Products section for the part numbers.
103
MAINTENANCE
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 box.
1. View the fluid level in the bottle.
2. If the level is low, 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).
3. Reinstall the cap.
4. Close and secure the front box and cover.
RADIATOR COOLANT
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every five (5) years and fresh
Antifreeze 50/50 Premix added.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has
run dry, check the level in the radiator. Add coolant as needed.
CAUTION
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. Access the pressure cap under the front box. See the Front Compartment
section for details.
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 function properly. Your POLARIS dealer can provide
the correct replacement part.
5. Close and secure the front box and cover.
104
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.
WARNING
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 the Master Cylinder/Brake
Fluid section for details.
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 .030” (0.762 mm).
5. Check the security and surface condition of the disc. Clean any grease using
a recommended 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.
SEAT REMOVAL
1. Locate the seat removal latch in the center of the seat’s rear.
2. Pull on the latch handle to disengage the seat from the vehicle’s frame.
3. Remove the seat.
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MAINTENANCE
TIRES
WARNING
Operating your ATV 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 for recommended tire type, size and pressure.
TIRE TREAD DEPTH
Always replace tires when tread depth
is worn to 3 mm (1/8”) or less.
FRONT WHEEL HUB TIGHTENING
Front wheel bearing tightness and spindle nut retention are critical component
operations. All service must be performed by your authorized dealer or other
qualified service facility.
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MAINTENANCE
WHEEL REMOVAL
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
WARNING
Do not service axle nuts that have a cotter pin installed. Your authorized dealer
can assist.
5. Elevate the side of the vehicle by placing a suitable stand under the foot rest
frame.
6. Remove the wheel nuts.
7. Remove the wheel.
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.
WARNING
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 loosened for
service.
WHEEL TYPE NUT TORQUE
All 120 ft-lbs (163 Nm)
107
MAINTENANCE
TOE ALIGNMENT
WARNING
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 or other qualified service facility.
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).
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. 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
q
and rear
w
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.
108
MAINTENANCE
AIR FILTER INSTALLATION
1. Remove the seat, the air box cover strap, and remove the air box cover.
2. Remove the filter.
3. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in
soapy water, then rinse and let dry.
4. Reinstall the pre-filter over the main filter. Install a new main filter if needed.
5. Reinstall the filter into the air box.
6. Reinstall the air box cover and the seat.
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 circuits that may have
caused the blown fuse, then replace the fuse.
Spare fuses are provided in the fuse box.
1. Access the fuses under 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. Close and secure the front box and cover.
LIGHTS
CAUTION
Poor lighting can result in reduced visibility when driving. Headlight and taillight
lenses become dirty during normal operation. Clean headlights frequently and
replace burned out headlamps promptly.
Always make sure lights are adjusted properly for best visibility.
109
MAINTENANCE
HEADLIGHT LAMP REPLACEMENT
When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil
from your skin leaves a residue, causing a hot spot that will shorten the life of the
lamp. If fingers do touch a lamp, clean it with denatured alcohol.
CAUTION
Hot components can cause burns to skin. Allow lamps to cool before servicing.
1. Remove the four (4) headlight pod screws. Pull the pod cover forward.
2. Unplug the headlamp from the wiring harness. Be sure to pull on the
connector, not on the wiring.
3. Turn the lamp counter-clockwise to remove it.
4. Install the new lamp. Make sure the tab on the lamp locates properly in the
housing.
5. Reassemble the pod.
HIGH BEAM ADJUSTMENT
The headlight beam can be adjusted slightly upward or downward. Use the
following procedure to make the adjustment.
110
MAINTENANCE
1. Position the vehicle on a level surface with the headlight approximately 25 ft.
(7.6 m) from a wall
q
. 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 2 in. (5 cm) below the mark on the wall
w
. Include rider
weight on the seat when measuring.
5. The adjustment screw is located on the left side of the headlight pod. To
adjust the beam, loosen the screw. Adjust the headlamp to the desired
position, then tighten the screw.
LOW BEAM ADJUSTMENT
The low beam can be adjusted slightly upward or downward by rotating the
adjustment screw, located on either side of the vehicle.
HEADLIGHT HOUSING REPLACEMENT
1. Remove the four (4) headlight pod screws.
2. Pull the pod cover forward.
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 from the bracket for removal.
6. Reverse the steps to install the new housing and reassemble the pod.
LOWER HEADLAMP REPLACEMENT
1. Turn the back of the headlight harness counter-clockwise and pull the
harness assembly away from the headlight assembly.
2. Remove the headlamp and install the new headlamp.
3. Reinstall the harness assembly into the headlight assembly.
NOTE
Take care to avoid touching the glass on the new headlight bulb. Fingerprints
on the glass may result in premature failure.
4. Turn the headlight harness clockwise to secure the headlamp.
111
MAINTENANCE
TAILLIGHTS/BRAKE LIGHTS REPLACEMENT
Procedure to replace taillights:
TO REPLACE LEFT TAILLIGHT:
1. Remove the harness connector from the back of the light assembly.
2. Remove the 3 fasteners securing the light assembly and remove the light
assembly.
3. Install the new light assembly and tighten the 3 fasteners to secure the light
assembly.
4. Reinstall the harness connector. Test the light for proper operation
TO REPLACE RIGHT TAILLIGHT:
1. Remove the heat shield covering the light assembly.
2. Remove the harness connector from the back of the light assembly.
3. Remove the 3 fasteners securing the light assembly, and then remove the
assembly.
4. Install the new light assembly, then re-affix and tighten the 3 fasteners.
5. Reinstall the harness connector.
6. Reinstall the heat shield.
7. Test the light for proper operation.
TO REPLACE CENTER TAILLIGHT:
1. Remove the rear rack and rear storage box.
2. Remove the harness connector from the back of the light assembly.
3. Remove the 4 fasteners securing the light assembly, and then remove the
assembly.
4. Install the new light assembly, then re-affix and tighten the 4 fasteners.
5. Reinstall the harness connector.
6. Reinstall the rear rack and rear storage box.
7. Test the light for proper operation.
112
MAINTENANCE
SPARK PLUGS
SPARK PLUG RECOMMENDATIONS
Refer to the specifications section for the recommended 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 or their equivalent.
PLUG CONDITION TORQUE SPECIFICATION
New Spark Plug 18-20 ft-lbs
(24-27 Nm)
Previously Installed Spark Plug 18-20 ft-lbs
(24-27 Nm)
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.
CAUTION
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection. Allow engine to cool before
removing spark plug wire.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Rotate the spark plug counter-clockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specification.
NORMAL 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 indicates the proper
type and heat range for the engine and the service.
The tip should not be white. A white insulator tip indicates overheating, caused
by use of an improper spark plug or incorrect throttle body adjustments.
113
MAINTENANCE
WET FOULED 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 poor fuel quality.
VEHICLE IMMERSION
If your vehicle becomes immersed,
major engine damage can result if the
machine is not thoroughly inspected.
Take the vehicle in for service before
starting the engine. Your POLARIS
dealer can provide this service.
If it's impossible to take your ATV to a
dealer before starting it, follow the
steps outlined below.
1. Move the ATV 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. If equipped, remove the air box drain plug
q
to drain water.
Reinstall the drain plug. Make sure the E-ring is on the drain plug and
reinstall the drain plug.
NOTICE
Serious damage could occur if the air box drain plug is not reinstalled and
tightened properly.
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 procedure.
NOTICE
Serious damage can occur after immersion if fluids are not changed promptly.
Your authorized dealer can assist.
7. Take the vehicle in for service as soon as possible, whether you succeed in
starting it or not. Your authorized dealer can provide the required service.
8. If water has been ingested into the PVT, follow the procedure in the PVT
System section for drying out the PVT.
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MAINTENANCE
SPARK ARRESTER
WARNING
• Never operate the vehicle without the spark arrester.
• Remove any combustible materials from the area.
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. Exhaust contains poisonous
carbon monoxide gas that can cause loss of consciousness or death in a
very short time.
• Do NOT perform service on the spark arrester while the system is HOT.
Exhaust system temperatures can reach extreme temperatures. Allow
components to cool sufficiently before proceeding.
• Do not stand behind or in front of the vehicle while purging the exhaust
system.
• Never go under the vehicle while it is inclined.
• Wear eye protection and gloves while servicing.
Periodically clean the spark arrester to remove accumulated carbon.
1. Place the transmission in PARK.
2. Remove the arrester retaining bolt and nut.
3. Remove the arrester from the end of the muffler.
4. Use non-synthetic brush to clean the arrester screen. A synthetic brush may
melt if the components are warm. If necessary, blow debris from the screen
with compressed air.
5. Inspect the screen for wear and damage. Replace a worn or damaged
screen.
6. Reinstall the arrester.
7. Torque the bolt to specification.
TORQUE
Spark Arrester Retaining Bolt: 9–11 ft. lbs. (12–15 Nm)
115
MAINTENANCE
PVT SYSTEM
WARNING
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 POLARIS dealer, or other qualified person, for service and repair
assistance.
• 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.
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 flyweights 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.
On POLARIS ATVs, the approximate gear ratio difference between high and low
range is 1:2.25. This difference in gearing affects the operation of the PVT,
especially at speeds less than 7 MPH (11 km/h), due to the system's
dependence 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.
116
MAINTENANCE
The air temperature in the clutch cover is substantially reduced by using low
range while operating at low ground speeds. Reducing the temperature inside
the clutch cover greatly extends the life of the PVT components (belt, cover,
etc.).
WHEN TO USE LOW RANGE AND HIGH RANGE
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
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 operating.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall 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 5
seconds.
5. Allow the engine RPM to settle to idle speed, then shift the transmission to
low range.
6. Test for belt slippage. If the belt slips, repeat the process. Your vehicle
requires service as soon as possible, which your authorized dealer can
provide.
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MAINTENANCE
BATTERY
WARNING
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 ATV is equipped with a sealed battery, which requires little maintenance.
POLARIS does not recommend using a conventional battery in this vehicle. The
orientation of the battery could result in electrolyte 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 terminals with dielectric grease or petroleum
jelly.
BATTERY REMOVAL
1. Access the battery under 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 ATV.
BATTERY INSTALLATION
Using a new battery that has not been fully charged can damage the battery and
result in a shorter life. It can also hinder vehicle performance. Follow the
instructions in the Battery Charging section before installing the battery.
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MAINTENANCE
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to operation in
extreme cold or due to extended use of multiple electrical accessories, your
authorized dealer can assist. Your dealer can provide any installation
procedures that may differ for an extreme use 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. Close and secure the front box and cover.
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.
119
MAINTENANCE
POLARIS recommends maintaining battery charge by using a POLARIS battery
trickle charger or by charging once a month using the battery charge port
q
.
The Polaris offered battery trickle charger can be left connected during the
storage period, and will automatically charge the battery if the voltage drops
below a pre-determined point. See the Polaris Products section for the part
number.
IMPORTANT
Polaris recommends using a trickle charger that shuts off automatically when
the battery is fully charged. If you are not using a trickle charger that
automatically shuts when the battery is fully charged, make sure to monitor the
battery charge level and disconnect the charger when the battery is fully
charged.
CAUTION
When using a battery trickle charger, always place the charger on the ground,
or on a suitable elevated surface. Never place the charger on the vehicle or let
it hang from the battery charge port while plugged in.
BATTERY CHARGING
The following battery charging instructions apply only to the installation 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.
WARNING
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.
120
MAINTENANCE
For a refresh charge, follow all instructions carefully.
1. The battery should be disconnected from a load or charger for at least two
hours before checking voltage. Check the battery voltage with a voltmeter or
multimeter. A fully charged battery will register 12.6 V or higher.
2. If the voltage is less than 12.6 volts, recharge the battery at 1.2 amps or less
until battery voltage is 12.6 or greater.
3. When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
following guidelines via the table below.
BATTERY CHARGING (SEALED BATTERY)
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% 12.6-12.8 volts Conventional/Low
Maintenance Battery:
check after 60 days
AGM Battery: check
after 30 days
None required
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 AGM ONLY: needs
charge with
desulfating charger
At least 20 hours
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MAINTENANCE
BATTERY IDENTIFICATION
IMPORTANT
It is important to identify the type of battery installed in the vehicle. Different
types of batteries require different service procedures. Proper servicing and
upkeep of the battery is very important for maintaining long battery life. All
Polaris ORV models include either a Conventional battery or a Low
Maintenance battery.
CONVENTIONAL BATTERY
• The battery is NOT activated when
packaged
• Distilled water and electrolyte added
as required
• Removable cap plugs located on top
of battery
• Vent tube located on side of battery
LOW MAINTENANCE BATTERY
• Battery activated when packaged
• Distilled water and electrolyte
NEVER added
• Non removable cap(s) located on top
of battery
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MAINTENANCE
LEAD ACID CONVENTIONAL / DRY SHIPPED AGM
BATTERY BEST PRACTICES
Some Polaris ORV models include either a Lead Acid Conventional battery or a
Dry Shipped Absorbed Glass Mat (AGM) battery. See the Service Manual for
procedures on how to activate, charge, maintain, and test a Lead Acid
Conventional or Dry Shipped AGM battery.
NOTICE
Using a new battery that has not been fully charged can damage the battery
and result in a shorter life. It can also hinder vehicle performance.
LEAD ACID CONVENTIONAL BATTERIES
ACTIVATION
NOTE
A Polaris battery purchased from a Polaris dealership should be activated at
time of purchase by the dealer.
• Do NOT activate the battery unless it will be put into regular service within 30
days. Bulk acid should be used to activate the battery.
• Always remove the sealing cap from the vent elbow before activating the
battery. Never put the sealing cap back onto the battery. The gas pressure
can cause the battery to rupture.
• Let the battery sit for 30 minutes after you add the initial electrolyte. Once
absorbed, fill the battery with additional electrolyte to the upper line of the
electrolyte level indicator. This is the only time that electrolyte should be
added to the battery.
• Once the battery is fully charged, replace cap plugs by hand. Do NOT use a
tool to install the cap plugs.
CHARGING
• The battery must be fully charged before use or battery life will be significantly
reduced by 10-30% of the battery's full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls
below 12.5V, charge it immediately, or the battery service life and vehicle
performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (PN
2830511) charger (or a similar charger), which can be ordered through your
normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s
amp-hour rating.
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MAINTENANCE
MAINTENANCE
• Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, battery service
life and vehicle performance may be adversely affected.
• Never add any electrolyte to the battery once the battery is in service. After
the battery is initially activated, only distilled water should be added to
maintain electrolyte levels.
• Store the battery in the vehicle with the cables disconnected, or store the
battery in a cool / dry location. Batteries will self discharge more rapidly when
stored in extreme temperatures.
TESTING
• If the test fails, fully charge the battery.
• Proper load testing of the battery requires special equipment and can be
performed by your dealer.
DRY SHIPPED AGM BATTERIES
ACTIVATION
• Do NOT activate the battery unless it will be put into regular service within 30
days. Only use the electrolyte container supplied with the battery to activate
the battery.
• Keep the electrolyte container in place for 20 minutes or longer until the
container is completely empty. If necessary, gently tap the container to empty
it.
• Once the battery is fully charged, replace the strip of caps by hand. Do NOT
use a tool to install the strip.
CHARGING
• Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (PN
2830438) charger, which can be ordered through your normal parts channel.
• Nominal voltage is 12.8 Volts when fully charged. If the voltage falls below
12.5V, charge it immediately, or the battery runs the risk of sulfation.
MAINTENANCE
• Never add any electrolyte or distilled water to the battery once the battery is in
service.
• If you do not drive the vehicle for more than TWO weeks, maintain the battery
with the BatteryMINDer® 2012 AGM - 2 AMP (PN 2830438) charger.
• If you plan to store the vehicle for ONE month or longer, remove the battery
from the vehicle and store the battery in a cool / dry location. Continue to
maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (PN
2830438) charger and inspect the battery every 60 days.
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MAINTENANCE
TESTING
• If the test fails, fully charge the battery.
• If the battery is too low to accept a charge, see the AGM Battery Charging -
Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
• Proper load testing of the battery requires special equipment and can be
performed by your dealer.
LOW MAINTENANCE BATTERY BEST PRACTICES
Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat
(AGM) Low Maintenance battery. See the Service Manual for procedures on
how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.
NOTICE
Using a new battery that has not been fully charged can damage the battery
and result in a shorter life. It can also hinder vehicle performance.
LEAD ACID LOW MAINTENANCE BATTERY
CHARGING
• The battery must be fully charged before use or battery life will be significantly
reduced by 10-30% of the battery's full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls
below 12.5V, charge it immediately, or the battery service life and vehicle
performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (PN
2830511) charger (or a similar charger), which can be ordered through your
normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s
amp-hour rating.
MAINTENANCE
• Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, hard crystal
sulfation will form on the plates, reducing the efficiency and service life of the
battery.
• Never add electrolyte or distilled water to the battery. Doing so will damage
the case and shorten the life of the battery.
• Store the battery in the vehicle with the cables disconnected, or store the
battery in a cool / dry location. Batteries will self discharge more rapidly when
stored in extreme temperatures.
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MAINTENANCE
TESTING
• Test the battery using the PU-50296 battery tester.
• Proper load testing of the battery requires special equipment and can be
performed by your dealer.
AGM LOW MAINTENANCE BATTERIES
CHARGING
• Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (PN
2830438) charger, which can be ordered through your normal parts channel.
• Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls
below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
MAINTENANCE
• Never add electrolyte or distilled water to the battery. Doing so will damage
the case and shorten the life of the battery.
• If you do not drive the vehicle for more than TWO weeks, maintain the battery
with the BatteryMINDer® 2012 AGM - 2 AMP (PN 2830438) charger.
• If you plan to store the vehicle for ONE month or longer, remove the battery
from the vehicle and store the battery in a cool / dry location. Continue to
maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (PN
2830438) charger and inspect the battery every 60 days.
TESTING
• If the test fails, fully charge the battery.
• If the battery is too low to accept a charge, see the AGM Battery Charging -
Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
• Proper load testing of the battery requires special equipment and can be
performed by your dealer.
CAMBER AND CASTER
The camber and caster are non-adjustable.
126
MAINTENANCE
SUSPENSION ADJUSTMENT
FRONT/REAR SPRING PRELOAD ADJUSTMENT
The factory setting is appropriate for nearly all
riding conditions. If desired, the suspension may
be adjusted to maintain vehicle clearance height
when carrying loads.
To adjust the preload, do the following:
1. Elevate the vehicle to allow the suspension to
fully extend.
2. Turn the adjusting ring to the left to increase
preload for a higher ride height. Turn the
adjusting ring to the right to decrease preload
for a lower ride height.
FACTORY PRELOAD SETTINGS
Sportsman
XP 1000 S
Front
Suspension
15.75 in. (40
cm)
Rear
Suspension
15.56 in. (39.5
cm)
Follow these guidelines if
you make adjustments to this suspension.
• Always return the suspension to the factory setting after the load is removed
from the vehicle. The increased suspension height will negatively impact
vehicle stability when operating without a load.
• Always apply the same adjustment setting to both sides of the vehicle.
• Do not increase the spring preload by more than one inch (25.4 mm) over the
factory setting.
• When decreasing preload, make sure at least two turns of preload are holding
the spring between the retainer on the top of the shock and the threaded
spring preload adjuster nut on the shock body. Failure to do so could cause
the retainer to fall off when the suspension is fully extended.
127
MAINTENANCE
FRONT/REAR SHOCK COMPRESSION
ADJUSTMENT
To adjust the compression dampening,
do the following:
1. Turn the clicker clockwise to
increase compression damping.
2. Turn the clicker counter-clockwise to
decrease compression damping.
NOTE
Always adjust the clicker at least one click below full stiff (full clockwise) or
shock damage will occur.
FACTORY CLICKER SETTINGS
Front Suspension 8 Clicks from Full Stiff
Rear Suspension 8 Clicks From Full Stiff
CROSSOVER RING ADJUSTMENT
To adjust the preload, do the following:
1. Elevate the vehicle to allow the
suspension to fully extend.
2. Using the spanner tool included with
the vehicle, unlock the cross-over
adjustment ring.
3. Adjust cross-over ring to desired
location.
4. Lock the cross-over adjustment ring.
CROSSOVER RING FACTORY
SETTINGS
Front Suspension 2.13 in. (5.4 cm)
128
MAINTENANCE
HANDLEBARS
The handlebars can be adjusted for rider preference.
WARNING
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 specification, then torque the rear two bolts. A
gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.
TORQUE
Handlebar bolts:
14 ft-lbs +/- 10% (19 Nm +/- 10%)
5. Reinstall the headlight pod.
129
MAINTENANCE
CLEANING AND STORAGE
WASHING THE VEHICLE
NOTICE
The use of a high pressure washer may damage the instrument cluster. Wash
the vehicle by hand or with a garden hose using mild soap. 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.
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 decals. Avoid directing the water stream at the following items:
• Wheel bearings
• Radiator
• Transmission seals
• Cab and body panels
• Electrical components
• Switches and controls
• Fuel system components
• Labels and decals
If an informational or graphic label becomes illegible or comes off, contact 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.
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.
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.
130
MAINTENANCE
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.
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 the
Washing the Vehicle section.
STABILIZE THE FUEL
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or
equivalent fuel treatments or stabilizers. Follow the instructions on the
container for the recommended 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.
OIL AND FILTER
Change the oil and filter. See the Engine Oil section.
AIR FILTER / AIR BOX
Replace the air filter. See Maintenance Chapter. Clean the air box.
FLUID LEVELS
Inspect the fluid levels. Add or change fluids as recommended in the Periodic
Maintenance Chart.
• Demand drive fluid (front gearcase)
• Rear gearcase fluid (if equipped)
• Transmission fluid
131
MAINTENANCE
• Brake fluid (change every two years and any time the fluid looks dark or
contaminated)
• Coolant (test strength/fill)
INSPECT AND LUBRICATE
Inspect all cables and lubricate all areas of the vehicle as recommended in the
Periodic Maintenance Chart.
FOG THE ENGINE
1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel
treatment. Follow the instructions on the container. Start the engine. Allow it
to idle for several minutes so the Carbon Clean reaches the injectors. Stop
the engine.
2. Remove the spark plugs and add 1–1.5 oz. (29.5–44 cc.) of engine oil. To
access the plug holes, use a section of clear 6 mm (1/4”) hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil. Do this
carefully! If you miss the plug holes, oil will drain from the spark plug cavities
into the hole at the front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall
the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around the
piston rings and ring lands, coating the cylinder with a protective film of fresh
oil.
6. Reinstall the spark plug caps.
7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
BATTERY MAINTENANCE
See the Battery Storage and Battery Charging sections for storage and
charging procedures.
STORAGE AREA / COVERS
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 condensation, and may promote corrosion and
oxidation.
132
MAINTENANCE
TRANSPORTING THE ATV
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap and seats.
5. Always tie the frame of the ATV to the transporting unit securely with suitable
straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks
or handlebars.
6. Remove the key to prevent loss during transporting.
133
MAINTENANCE
134
SPECIFICATIONS
SPORTSMAN XP 1000 S
SPECIFICATIONS
Maximum Weight Capacity 715 lbs. (324 kg) (includes operator, cargo and
accessories)
Dry Weight 970 lbs. (440 kg)
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Rear Gearcase Oil Capacity 7.1 oz. (210 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Transmission Oil Capacity 37 oz. (1100 ml)
Front Rack/Storage Box Capacity 200 lbs. (91 kg)
Rear Rack Capacity 300 lbs. (136 kg)
Receiver Hitch Tongue Capacity 175 lbs. (79 kg) (Rear rack load and tongue
weight not to exceed 300 lbs./136 kg)
Hitch Towing Rating 1750 lbs. (794 kg)
Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)
Overall Length 83.25 in. (211 cm)
Overall Width 55 in. (140 cm)
Overall Height 49 in. (124.5 cm)
Wheelbase 53 in. (134.6 cm)
Ground Clearance 14.5 in. (36.8 cm)
Minimum Turning Radius 84 in. (213 cm) unloaded
Engine EHO952LE
Displacement 952 cc
Bore x Stroke 90.5 x 74
Alternator Output 560w @3000 RPM
Compression Ratio 11:1
135
SPECIFICATIONS
SPECIFICATIONS
Starting System Electric
Ignition System Electronic Fuel Injection
Ignition Timing 6° +/- 5° BTDC @ 1200 RPM, Engine warm
Idle RPM 1200 +/- 50
Throttle Body/Size Mikuni® Dual Bore/42 mm
Spark Plug Type / Gap AUTOLITE® 5682 / .030 in. (0.76 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable
Transmission)
Front Suspension Dual a-arm with 11.5 in. (29 cm) travel
Rear Suspension Progressive rate with 14 in. (35.5 cm) travel
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires/Pressure, Front 27X9R14 / 10 psi (69 kPa)
Tires/Pressure, Rear 27X11R14 / 10 psi (69 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel
Brakes, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 1 Single Beam on Headlight Pod (50 watt) 2
Single Beam on Bumper (50 watt)
Taillights 0.26 watts
Brake Light 3.6 watts
Instrument Cluster Digital
136
SPECIFICATIONS
138
POLARIS PRODUCTS
LUBRICANTS / SERVICE PRODUCTS
PRODUCT
SIZE (QUANTITY)
PART NUMBER
Fogging Oil
12 oz aerosol (12)
2870791
1 qt (12)
2871517
PS-4
1 qt (12)
2876244
2 qt (8)
2877490
1 gal (4)
2876245
PS-4 Extreme Duty
1 qt (12)
2878920
2 qt (8)
2878922
1 gal (4)
2878919
AGL
1 qt (12)
2878068
1 gal (4)
2878069
Pump for Gallon Jug
3.8 l 2870465
Demand Drive
1 qt (12)
2877922
2.5 gal (2)
2877923
Antifreeze / Coolant
1 qt (12)
2880514
1 gal (6)
2880513
Grease Gun Kit, Premium All
Season
— 2871312
All Season Grease
Four 3 oz packs (6)
2871322
14 oz cartridge
2871423
Premium Starter Grease — 2871460
U-Joint Grease
3 oz tube (24)
2871515
14 oz cartridge
2871551
Dielectric Grease (Nyogel®)
— 2871329
Carbon Clean
12 oz bottle (12)
2871326
Fuel Stabilizer
16 oz (12)
2870652
2.5 gal (2)
2872280
DOT 4 Brake Fluid — 2872189
Loctite® 565 Thread Sealant — 2871956
POLARIS Battery Tender
Charger
— 2859044
139
POLARIS PRODUCTS
140
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.
Driving at low RPM or ground
speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at low
ambient temperatures
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 flexible and prevent belt
burning.
Slow/easy clutch engagement 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 rollover.
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 rollover.
Belt slippage from water or
snow ingestion into the PVT
system
Dry out the PVT. Prevent water from entering the PVT intake duct.
See Intake Pre-Filters for more information. Inspect clutch seals
for damage if repeated leaking occurs.
Clutch malfunction An authorized dealer can assist.
Poor engine performance
Check for fouled plug or foreign material in gas tank or fuel lines.
An authorized dealer can assist.
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.
141
TROUBLESHOOTING
ENGINE DOESN'T TURN OVER
POSSIBLE CAUSE SOLUTION
Low battery voltage Recharge the battery
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Loose electronic control box
connections
Inspect, clean, reinstall connectors
ENGINE TURNS OVER, FAILS TO START
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel
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 Inspect plug and replace if necessary
No spark to spark plug Inspect plug and replace if necessary
Water or fuel in crankcase Your authorized dealer can assist
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure Your authorized dealer can assist
ENGINE BACKFIRES
POSSIBLE CAUSE SOLUTION
Weak spark from spark plug Inspect, clean and/or replace spark plug
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug
wires
Your authorized dealer can assist
Mechanical failure Your authorized dealer can assist
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
142
TROUBLESHOOTING
ENGINE PINGS OR KNOCKS
POSSIBLE CAUSE SOLUTION
Poor quality or low octane fuel Replace with recommended fuel
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
ENGINE RUNS IRREGULARLY, STALLS OR
MISFIRES
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your authorized dealer can assist
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
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
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure Your authorized dealer can assist
ENGINE STOPS OR LOSES POWER
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel
Kinked or plugged fuel vent
line
Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your authorized dealer can assist
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
143
TROUBLESHOOTING
POSSIBLE CAUSE SOLUTION
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure Your authorized dealer can assist
Overheated engine Clean radiator screen and core, clean engine exterior, and check
coolant level. Your dealer can assist.
144
TROUBLESHOOTING
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.
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
Signal Out of Range
102 2
Crankshaft Position
Sensor
Circuit Fault
636 8
Plausibility Fault
636 2
Vehicle Speed Signal Speed Too High
84 8
Plausibility Fault
84 2
Gear Sensor Signal Voltage Too Low
523 4
Voltage Too Low
523 3
Signal Fault
523 2
145
TROUBLESHOOTING
DIAGNOSTIC CODES
COMPONENT CONDITION SPN FMI
Injector 1 (MAG) (SDI
Part Load)
Driver Circuit Open/
Grounded
651 5
Driver Circuit Short to
B+
651 3
Driver Circuit
Grounded
651 4
Injector 2 (PTO) (SDI
Part Load)
Driver Circuit Open/
Grounded
652 5
Driver Circuit Short to
B+
652 3
Driver Circuit
Grounded
652 4
Ignition Coil Primary
Driver 1 (MAG)
Driver Circuit Short to
B+
1268 3
Ignition Coil Primary
Driver 2 (PTO)
Driver Circuit Short to
B+
1269 3
Fuel Pump Driver
Circuit
Driver Circuit Open/
Grounded
1347 5
Driver Circuit Short to
B+
1347 3
Driver Circuit
Grounded
1347 4
Fan Relay Driver
Circuit
Driver Circuit Open/
Grounded
1071 5
Driver Circuit Short to
B+
1071 3
Driver Circuit
Grounded
1071 4
Idle Air Control Driver Circuit Open/
Grounded
634 5
Driver Circuit Short to
B+
634 3
Driver Circuit
Grounded
634 4
Position Out of Range
634 7
Starter Enable Circuit Driver Circuit Open/
Grounded
1321 5
146
TROUBLESHOOTING
DIAGNOSTIC CODES
COMPONENT CONDITION SPN FMI
Driver Circuit Short to
B+
1321 3
Driver Circuit
Grounded
1321 4
Chassis Relay Driver Circuit Open/
Grounded
520208 5
Driver Circuit Short to
B+
520208 3
Driver Circuit
Grounded
520208 4
All Wheel Drive
Control
Driver Circuit Open/
Grounded
520207 5
Driver Circuit Short to
B+
520207 3
Driver Circuit
Grounded
520207 4
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
Active Descent
Control System
Driver Circuit Open/
Grounded
520203 5
Driver Circuit Short to
B+
520203 3
Driver Circuit
Grounded
520203 4
Idle Speed Speed Too High
520211 3
Speed Too Low
520211 4
Right Hand Control Momentary Driveline
Mode Switch Press
520468 31
147
TROUBLESHOOTING
DIAGNOSTIC CODES
COMPONENT CONDITION SPN FMI
EPS MODELS ONLY
Vehicle Speed Sensor Data Valid But Above
Normal Operational
Range - Most Severe
Level
84 0
Data Erratic,
Intermittent Or
Incorrect
84 2
Abnormal Rate Of
Change
84 10
Received Network
Data In Error
84 19
System Power Data Valid But Above
Normal Operational
Range - Most Severe
Level
168 0
Voltage Above
Normal, Or Shorted To
High Source
168 3
Voltage Below
Normal, Or Shorted To
Low Source
168 4
Engine Speed Data Valid But Above
Normal Operational
Range - Most Severe
Level
190 0
Data Erratic,
Intermittent Or
Incorrect
190 2
Received Network
Data In Error
190 19
ECU Memory Bad Intelligent Device
Or Component
628 12
Out Of Calibration
628 13
Calibration Out Of Calibration
630 13
Steering Over Current
Shut Down
Current Above Normal
Or Grounded Circuit
520221 6
Steering Excessive
Current Error
Current Above Normal
Or Grounded Circuit
520222 6
148
TROUBLESHOOTING
DIAGNOSTIC CODES
COMPONENT CONDITION SPN FMI
EPS MODELS ONLY
Steering Torque
Partial Failure
Condition Exists
520223 31
Steering Torque Full
Failure
Condition Exists
520224 31
EPAS Inverter
Temperature
Data Valid But Above
Normal Operational
Range - Most Severe
Level
520225 0
Data Valid But Above
Normal Operating
Range - Moderately
Severe Level
520225 16
EPAS
Communications
Receive Data Error
Data Erratic,
Intermittent Or
Incorrect
520226 2
Condition Exists
520226 31
Position Encoder
Error
Root Cause Not
Known
520228 11
Bad Intelligent Device
Or Component
520228 12
Condition Exists
520228 31
EPAS Software Error Bad Intelligent Device
Or Component
520229 12
Condition Exists
520229 31
EPAS Power Save
Condition
Condition Exists
520231 31
EPS SEPIC Voltage
Error
Voltage Above
Normal, Or Shorted To
High Source
524086 3
Voltage Below
Normal, Or Shorted To
Low Source
524086 4
149
TROUBLESHOOTING
150
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS)
gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS
vehicle against defects in material or workmanship. POLARIS further warrants
that the spark arrester in this product will meet the efficiency requirements of
USFS standard 5100-1C for at least 1000 hours when subjected to normal use
and when maintenance and installation are in accordance with POLARIS
recommendations.
This warranty covers parts and labor charges for repair or replacement of
defective parts and begins on the date of purchase by the original retail
purchaser. This warranty is transferable to another owner during the warranty
period through a POLARIS dealer, or other qualified person, but any such
transfer will not extend the original term of the warranty. The duration of this
warranty may vary by international region based upon local laws and
regulations.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your
dealer and submitted to POLARIS within ten days of purchase. 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 your proof of warranty coverage. 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
trouble-free operation. Purchasing a machine in the crate or without proper
dealer set-up will void your warranty coverage.
151
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a
defect in material or workmanship. THIS WARRANTY DOES NOT COVER
CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of
God, accidental damage, normal wear and tear, abuse or improper handling.
This warranty also does not cover any vehicle, component, or part that has been
altered structurally, modified, neglected, improperly maintained or used for
racing, competition or purposes other than for which it was designed.
This warranty excludes damages or 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; snow,
water, dirt or other foreign substance ingestion/contamination; improper
maintenance; modified components; use of aftermarket or unapproved
components, accessories, or attachments; use of unapproved software or
calibration; unauthorized repairs; or repairs made after the warranty period
expires or by an unauthorized repair center.
This warranty excludes damages or failures caused by abuse, accident, fire, or
any other cause other than a defect in materials or workmanship and provides
no coverage for consumable components, general wear items, or any 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
• Suspension components
• Brake components
• Seat components
• Clutches and components
• Steering components
• Batteries
• Light bulbs/Sealed beam lamps
• Filters
• Lubricants
• Bushings
• Finished and unfinished surfaces
• Carburetor/Throttle body
components
• Engine components
• Drive belts
• Hydraulic components and fluids
• Circuit breakers/Fuses
• Electronic components
• Spark plugs
• Sealants
• Coolants
• Bearings
152
WARRANTY
LUBRICANTS AND FLUIDS
1. Mixing oil brands or using non-recommended oil may cause engine damage.
We recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or
fluids is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including
mileage, transportation costs, hotels, meals, shipping or handling fees, product
pick-up or delivery, replacement rentals, loss of product use, loss of profits, or
loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, 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 WARRANTY 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 PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES
DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
153
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS
Servicing Dealer. When requesting warranty service you must present your copy
of the Warranty Registration Form to the dealer. (THE COST OF
TRANSPORTATION 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.
IN THE COUNTRY WHERE YOUR PRODUCT WAS
PURCHASED:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS
dealer, or other qualified person. If you move or are traveling within the country
where your product was purchased, Warranty and Service Bulletin repairs may
be requested from any authorized POLARIS dealer, or other qualified person,
that sells the same line as your product.
OUTSIDE THE COUNTRY WHERE YOUR PRODUCT
WAS PURCHASED:
If you are traveling temporarily outside the country where your product was
purchased, you should take your product to an authorized POLARIS dealer, or
other qualified person. You must show the dealer photo identification from the
country of the selling dealer's authorized location as proof of residence. Upon
residence verification, the servicing dealer will be authorized to perform the
warranty repair.
IF YOU MOVE:
If you move to another country, be sure to contact POLARIS Customer
Assistance and the customs department of the destination country before you
move. Product importation rules vary considerably from country to country. You
may be required to present documentation of your move to POLARIS in order to
continue your warranty coverage. You may also be required to obtain
documentation from POLARIS in order to register your product in your new
country. You should warranty register your product at a local POLARIS dealer in
your new country immediately after you move to continue your warranty
coverage and to ensure that you receive information and notices regarding your
product.
IF YOU PURCHASE FROM A PRIVATE PARTY:
If you purchase a POLARIS product from a private party, to be kept and used
outside of the country in which the product was originally purchased, all warranty
coverage will be denied. You must nonetheless register your product under your
name and address with a local POLARIS dealer in your country to ensure that
you receive safety information and notices regarding your product.
154
WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT
IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S
AUTHORIZED LOCATION. This policy does not apply to products that have
received authorization for export from POLARIS. Dealers may not give
authorization for export. You should consult an authorized dealer to determine
this product's warranty or service coverage if you have any questions. This
policy does not apply to products registered to government officials or military
personnel on assignment outside the country of the selling dealer's authorized
location. This policy does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and
you have not followed the procedure set above, your product will no longer be
eligible for warranty or service bulletin coverage of any kind, other than safety
bulletins. Products registered to government officials or military personnel on
assignment outside of the country where the product was purchased will
continue to be covered by the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Dealership
contacts can be found via this website, if needed:
www.polaris.com/en-us/contact
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 from state to state or in different countries. If any of the above terms
are void because of federal, state, local law, all other warranty terms will remain
in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
155
WARRANTY
U.S.A. EPA EMISSIONS LIMITED WARRANTY
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is
first purchased, this emissions-certified vehicle is designed, built and equipped
so it conforms with applicable U.S. Environmental Protection Agency emission
regulations. POLARIS warrants that the vehicle is free from defects in materials
and workmanship that would cause it to fail to meet these regulations.
The warranty period for off road vehicles 100cc or greater emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues
for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever
comes first. The warranty period for ATVs less than 100cc emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues
for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever
comes first. This EPA emissions warranty period is extended for at least as long
as the standard factory warranty that Polaris provides on the vehicle as a whole.
The EPA emissions warranty period does not further extend if you purchase
additional warranty coverage in the form of a service contract or other paid
warranty extension, but emission-related parts may be covered subject to the
terms of any such paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle's regulated emissions, and it covers components of systems whose only
purpose is to control emissions. Repairing or replacing other components not
covered by this warranty is the responsibility of the vehicle owner. This
emissions limited warranty does not cover components whose failure does not
increase the vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts
related to the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for
exhaust emissions:
• Aftertreatment devices
• Crankcase ventilation valves
• Sensors
• Electronic control units
156
WARRANTY
The following parts are considered emission-related components for evaporative
emissions:
• Fuel Tank
• Fuel Cap
• Fuel Line
• Fuel Line Fittings
• Clamps*
• Pressure Relief Valves*
• Control Valves*
• Control Solenoids*
• Electronic Controls*
• Vacuum Control Diaphragms*
• Control Cables*
• Control Linkages*
• Purge Valves
• Vapor Hoses
• Liquid/Vapor Separator
• Carbon Canister
• Canister Mounting Brackets
• Carburetor Purge Port Connector
*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is
to reduce emissions or whose failure will increase emissions without significantly
degrading engine/equipment performance. The exclusive remedy for breach of
this limited warranty shall be, at the exclusive option of POLARIS, repair or
replacement of any defective materials, components or products. THE
REMEDIES SET FORTH IN THIS LIMITED 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
WARRANTY 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
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may
not apply if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents,
abuse or improper handling, maintenance or use. This limited warranty also
does not cover any engine that has been structurally altered, or when the vehicle
has been used in racing competition. This limited warranty also does not cover
physical damage, corrosion or defects caused by fire, explosions or other similar
causes beyond the control of POLARIS.
157
WARRANTY
Owners are responsible for performing the scheduled maintenance identified in
the owner's manual. POLARIS may deny warranty claims for failures that have
been caused by the owner's or operator's improper maintenance or use, by
accidents for which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the
emission control devices or systems on your vehicle. An authorized POLARIS
dealer, or other qualified person, can perform any service that may be necessary
for your vehicle. POLARIS also recommends POLARIS parts, however
equivalent parts may be used for such service. It is a potential violation of the
Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the
effectiveness of the vehicle's emission controls. Tampering with emission
controls is prohibited by federal law.
CALIFORNIA RESIDENTS
Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state
versions. Only the 50-state models are certified for sale in California. The 50-
state models available for sale in California are identified by the letter “B” in the
ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state
models are designed and built with features such as a reduced cargo box
capacity. Any modifications to these features may be a violation of the applicable
California regulations and may void this limited emissions warranty offered by
the manufacturer.
If you have any questions regarding your warranty rights and responsibilities,
please contact POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
158
WARRANTY
160
A
Active Descent Control (ADC)
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Age Restrictions. . . . . . . . . . . . . . . . . . . . . . . . 15
Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 131
Air Filter Installation . . . . . . . . . . . . . . . . . 109
All Wheel Drive System. . . . . . . . . . . . . . . 41
EVAP Models
2x4 Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ADC AWD Mode . . . . . . . . . . . . . . . . . 42
AWD Mode. . . . . . . . . . . . . . . . . . . . . . . . . 41
Automatic Transmission Gear
Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Auxiliary Foot Brake . . . . . . . . . . . . . 38, 105
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Identification. . . . . . . . . . . . . . . . . . . . . . . . 122
Battery Charging . . . . . . . . . . . . . . . . . . . . . 120
Battery Installation . . . . . . . . . . . . . . . . . . . . 118
Battery Maintenance . . . . . . . . . . . . . . . . 132
Battery Removal. . . . . . . . . . . . . . . . . . . . . . . 118
Battery Storage. . . . . . . . . . . . . . . . . . . . . . . . 119
Bluetooth Pairing. . . . . . . . . . . . . . . . . . . . . . . 57
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . 38
Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Brake System Break-in . . . . . . . . . . . . . . . 60
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
C
Camber and Caster. . . . . . . . . . . . . . . . . . 126
Cargo Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 76
Clean the Exterior . . . . . . . . . . . . . . . . . . . . 131
Cleaning and Storage . . . . . . . . . . . . . . . 130
Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cold Weather Operation. . . . . . . . . . . . . . 64
Cooling System. . . . . . . . . . . . . . . . . . . . . . . 103
Crankcase Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Crossing Hillsides. . . . . . . . . . . . . . . . . . . . . . 19
Crossover Ring Adjustment . . . . . . . 128
D
Descending Hills Improperly . . . . . . . . 19
Diagnostic Display Code
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Disengaging Active Descent
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Drive Belt Wear/Burn. . . . . . . . . . . . . . . . 141
Drive Line Switch. . . . . . . . . . . . . . . . . . . . . . . 35
Drive Mode Switch . . . . . . . . . . . . . . . . . . . . . 35
Driving Over Obstacles . . . . . . . . . . . . . . . 72
Driving Procedures
Driving Downhill . . . . . . . . . . . . . . . . . . . . . 68
Driving in Reverse . . . . . . . . . . . . . . . . . .
73
Driving on a Sidehill
(Sidehilling) . . . . . . . . . . . . . . . . . . . . . . . . . 69
Driving on Slippery Surfaces . . . . . 66
Driving Through Water. . . . . . . . . . . . . 71
Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . 67
E
Electromagnetic Interference . . . . . . . 89
Electronic Power Steering (EPS). . . 39
Emissions Limited Warranty. . . . . . . 156
Engaging Active Descent
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Engine and Drivetrain Break-in . . . . . 60
Engine Backfires . . . . . . . . . . . . . . . . . . . . . 142
Engine Doesn't Turn Over . . . . . . . . . 142
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Engine Pings or Knocks . . . . . . . . . . . . 143
Engine Runs Irregularly, Stalls
or Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Engine Stops or Loses Power . . . . 143
Engine Turns Over, Fails to
Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
European Vibration and Noise . . . . . . . . 9
Exhaust Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Exported Products . . . . . . . . . . . . . . . . . . . 155
Exposure to Exhaust . . . . . . . . . . . . . . . . . . 17
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 14
161
F
Failure to Inspect Before
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Fluid Part Numbers . . . . . . . . . . . . . . . . . . 139
Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 132
Front Compartment. . . . . . . . . . . . . . . . . . . . 39
Front Gearcase (Demand
Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Front Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Front Wheel Hub Tightening . . . . . . 106
Front/Rear Shock Compression
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . 131
Fuse Replacement. . . . . . . . . . . . . . . . . . . 109
G
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
H
Hand Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Handling Gasoline . . . . . . . . . . . . . . . . . . . . . 16
Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Headlight Housing
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 111
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 34
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
High Beam Adjustment . . . . . . . . . . . . . . 110
Hitch Capacity Label . . . . . . . . . . . . . . . . . . 30
Hot Exhaust Systems . . . . . . . . . . . . . . . . . 25
How To Obtain Warranty
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
I
Improper Cargo Loading . . . . . . . . . . . . . 24
Improper Hill Climbing . . . . . . . . . . . . . . . . 19
Improper Tire Maintenance . . . . . . . . . . 22
Inspect and Lubricate . . . . . . . . . . . . . . . 132
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 43
Back Light Color. . . . . . . . . . . . . . . . . . . . . 54
Back Light Level. . . . . . . . . . . . . . . . . . . . . 55
Bluetooth® (if equipped) . . . . . . . . . . 57
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Diagnostic Code. . . . . . . . . . . . . . . . . . . . . 50
Display Area 1 . . . . . . . . . . . . . . . . . . . . . . . 47
Display Area 2 . . . . . . . . . . . . . . . . . . . . . . . 48
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . 45
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 49
Service Hours. . . . . . . . . . . . . . . . . . . . . . . . 56
Unit Selection Distance . . . . . . . . . . . . 51
Unit Selection Temperature. . . . . . . 52
J
Jumps and Stunts. . . . . . . . . . . . . . . . . . . . . . 19
K
Know Your Riding Area/Tread
Lightly!® . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63
L
Lead Acid Conventional
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Lead Acid Low Maintenance
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Headlight Lamp
Replacement . . . . . . . . . . . . . . . . . . . . . . 110
Low Beam Adjustment. . . . . . . . . . . . 111
Limited Warranty . . . . . . . . . . . . . . . . . . . . . 151
Lower Headlamp Replacement. . . . 111
Lubricants / Service Products . . . . . 139
Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . 95
M
Maintenance Chart Key . . . . . . . . . . . . . . 92
Maintenance Log. . . . . . . . . . . . . . . . . . . . . 159
Master Cylinder/Brake Fluid . . . . . . . . . 36
Modifications to Vehicle . . . . . . . . . . . . . . 26
162
N
New Operator Driving
Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Noise Emission Control System . . . . 89
O
Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Oil and Filter Change. . . . . . . . . . . . . . . . . . 98
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Oil Recommendations . . . . . . . . . . . . . . . . 96
Operating at Excessive Speeds . . . . 18
Operating Improperly in Reverse. . . 22
Operating in Unfamiliar Terrain . . . . . 21
Operating on Frozen Bodies of
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating on Pavement . . . . . . . . . . . . . . 17
Operating on Public Roads . . . . . . . . . . 17
Operating on Slippery Terrain . . . . . . . 21
Operating on Steep Hills . . . . . . . . . . . . . 21
Operating Over Obstacles . . . . . . . . . . . 22
Operating Through Water . . . . . . . . . . . . 23
Operation on Public Lands in
the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
P
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Parking on an Incline . . . . . . . . . . . . . . . . . . 75
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . 74
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 139
Periodic Maintenance. . . . . . . . . . . . . . . . . 91
Severe Use Definition . . . . . . . . . . . . . . 92
Physical Control of the Vehicle . . . . . 18
Physical Skills. . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Polaris Products. . . . . . . . . . . . . . . . . . . . . . 139
Polishing the Vehicle . . . . . . . . . . . . . . . . 130
Poor Visibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Steering Unit (Cleaning). . . 103
Pre-Ride Checklist. . . . . . . . . . . . . . . . . . . . . 61
Protective Apparel . . . . . . . . . . . . . . . . . . . . . 17
PVT Break-in (Clutches/Belt) . . . . . . . 60
PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
R
Rack/Box Warning . . . . . . . . . . . . . . . . . . . . . 28
Radiator Coolant . . . . . . . . . . . . . . . . . . . . . 104
Radio Compliance Statements . . . . . . . 9
Rear Gearcase Oil . . . . . . . . . . . . . . . . . . . 102
Recovery Bottle Coolant . . . . . . . . . . . 104
Registration, Warranty . . . . . . . . . . . . . . 151
Reporting Safety Defects
(Canada). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
S
Safe Operation Practices . . . . . . . . . . . . 62
Safe Riding Gear . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Labels and Locations . . . . . . . . 27
Age 16 Warning . . . . . . . . . . . . . . . . . . . . . 27
Clutch Cover Warning. . . . . . . . . . . . . . 30
Discretionary Warning . . . . . . . . . . . . . 28
General Warning . . . . . . . . . . . . . . . . . . . . 29
No Passenger Warning . . . . . . . . . . . . 29
Reverse Override/AWD
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Training. . . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . 15
Safety, Winch Maintenance. . . . . . . . . . 88
Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . 105
Shock Loading the Winch . . . . . . . . . . . . 87
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Skidding or Sliding . . . . . . . . . . . . . . . . . . . . . 23
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . 115
Spark Plug Inspection. . . . . . . . . . . . . . . . 113
Spark Plug Recommendations . . . . 113
Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Specifications
Sportsman XP 1000 S . . . . . . . . . . . 135
Spring Preload Adjustment . . . . . . . . 127
Stabilize the Fuel. . . . . . . . . . . . . . . . . . . . . 131
Stalling While Climbing a Hill. . . . . . . . 20
Starting the Engine . . . . . . . . . . . . . . . . . . . . 63
Steering Assembly. . . . . . . . . . . . . . . . . . . 103
Stopping the Vehicle . . . . . . . . . . . . . . . . . . 74
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Switches
Engine Stop Switch . . . . . . . . . . . . . . . . . 33
163
Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . 32
Mode/Reverse Override
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
T
Taillights/Brake Lights
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 112
Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tire Pressure/Load Warning. . . . . . . . . 30
Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . 106
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Toe Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 108
Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Trailer Hitch Warning . . . . . . . . . . . . . . . . . . 25
Transmission Oil. . . . . . . . . . . . . . . . . . . . . . 100
Transporting the ATV. . . . . . . . . . . . . . . . 133
Turning Around on a Hill (K-
Turn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Turning Improperly. . . . . . . . . . . . . . . . . . . . . 18
U
Unauthorized Use of the Vehicle . . . 25
V
Vehicle Break-in Period. . . . . . . . . . . . . . . 59
Vehicle Identification Numbers . . . . . 11
Vehicle Immersion . . . . . . . . . . . . . . . . . . . . 114
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . 8
Washing the Vehicle. . . . . . . . . . . . . . . . . 130
Welcome Page . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . . 114
Wheel Installation . . . . . . . . . . . . . . . . . . . . 107
Wheel Nut Torque
Specifications. . . . . . . . . . . . . . . . . . . . . . . . 107
Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . 107
Winch
Winch Operation . . . . . . . . . . . . . . . . . . . . 81
Winch Safety Precautions . . . . . . . . 79
Winch Cable Care . . . . . . . . . . . . . . . . . . . . . 86
Winch Maintenance and
Service Safety. . . . . . . . . . . . . . . . . . . . . . . . . 88
Winch Shock Loading . . . . . . . . . . . . . . . . . 87
164
For your nearest Polaris dealer,
call 1-800-POLARIS (765-2747)
or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55
Medina, MN 55340
Part No. 9931371 Rev 01
Printed in USA
Never operate:
• without proper training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger - passengers affect balance and steering
and can increase risk of losing control
Always:
• use proper riding techniques to avoid vehicle overturns on
hills and rough terrain and in turns
• avoid paved surfaces - pavement may seriously affect
handling and control
SCAN CODE FOR PRDUCT AND SAFETY
INFORMATION. FOLLOW ALL INSTRUCTIONS
AND WARNINGS
Improper ATV use can result in SEVERE INJURY or DEATH.
WARNING
ALWAYS USE AN
APPROVED
HELMET AND
PROTECTIVE GEAR
NEVER USE ON
PUBLIC ROADS
NEVER CARRY
PASSENGERS
NEVER USE WITH
DRUGS OR
ALCOHOL
