2018
OWNER’S MANUAL
SCRAMBLER® 850
SCRAMBLER XP® 1000 EPS
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.
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 expect 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.
!
A card containing important ATV safety information should be attached to
the owner’s manual on the next page. If you cannot locate this card, or if it
has been removed, please call 1–800–342–3764 for assistance.
2018 Owner’s Manual
Scrambler® 850
Scrambler® XP 1000 EPS
POLARIS® and SCRAMBLER® are trademarks of POLARIS Industries Inc.
Copyright 2017 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.
2018 SCRAMBLER 850 / SCRAMBLER XP 1000 Owner’s Manual
9929658
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.
• Snowmobiles
• SPORTSMAN® All-terrain vehicles
• Low emission vehicles (LEVs)
• RANGER
® utility vehicles
• BRUTUS® work vehicles
• SLINGSHOT® three wheel
motorcycles
• RZR® sport vehicles
• GEM® vehicles
• INDIAN® motorcycles
• POLARIS POWER® generators
• POLARIS DEFENSE® combat
vehicles
• Timbersled® Snow Bikes
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.
3
WELCOME
Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 11
Features and Controls . . . . . . . . . . . . . . 27
Operation . . . . . . . . . . . . . . . . . . . . 43
Winch Guide. . . . . . . . . . . . . . . . . . . 61
Emission Control Systems . . . . . . . . . . . . . 71
Maintenance . . . . . . . . . . . . . . . . . . 73
Specifications . . . . . . . . . . . . . . . . . . 107
POLARIS Products . . . . . . . . . . . . . . . . 113
Troubleshooting . . . . . . . . . . . . . . . . . 115
Warranty . . . . . . . . . . . . . . . . . . . . 119
Maintenance Log . . . . . . . . . . . . . . . . 127
5
6
INTRODUCTION
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 (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 read this
manual and all product labels and has completed a certified safety training
course (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
SAFETY ALERT WARNING indicates a hazardous situation which, if not
avoided, COULD result in serious injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not
avoided, COULD result in minor to moderate injury.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
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
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers and key number in the spaces
provided. Remove the spare key and store it in a safe place. An ignition key can
be duplicated only by ordering a POLARIS key blank (using your key number)
and mating it with one of your existing keys. The ignition switch must be
replaced if all keys are lost.
The manufacturer’s label is located on the front right side of the vehicle behind
the radiator.
Vehicle Model Number (VIN)
q
Frame VIN
Engine Serial Number
w
Key Number
9
INTRODUCTION
10
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.
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.
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.
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, over-the-ankle boots and
seat belt (if equipped) 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
11
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.
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.
12
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 vehicle without proper instruction increases the risk of an
accident. The operator must understand how to operate the vehicle properly in
different situations and on different types of terrain.
All operators must read and understand the owner's
manual and all warning and instruction labels before
operating the vehicle.
All operators should review the safety DVD provided
with this vehicle and take a ROHVA training course
(www.rohva.org).
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY. Operation
is prohibited for anyone under 16 years of age or
anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and both
hands on the steering wheel (if equipped) or
handlebars.
USING ALCOHOL OR DRUGS
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
13
SAFETY
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.
• 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.
EXPOSURE TO EXHAUST
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 WITH PASSENGERS
• Never carry a passenger on a 1–up vehicle (Type I).
• Never carry more than one passenger on a 2–up
vehicle (Type II).
• Do not carry a passenger on a 2–up vehicle until
you have at least two hours of driving experience.
14
SAFETY
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).
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
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.
15
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.
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 a 1-up ATV on hills steeper than 25 degrees.
16
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 move the 4X4 switch to 4WDC (if equipped)
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.
• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.
• When fully stopped, apply the rear 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.
17
SAFETY
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.
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.
18
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
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. See page 48.
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.
IMPROPER CARGO LOADING
Overloading the vehicle or carrying/towing 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.
19
SAFETY
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
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.
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. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush, and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
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.
20
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.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
21
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
General Warning
t
Clutch Warning (Under Seat)
w
Reverse Override Warning
y
“No Passenger” Warning
e
Age Warning
u
Tire Pressure/Load Warning
r
4x4 Caution
i
Rack Warning
22
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.
REVERSE OVERRIDE WARNING/AWD CAUTION
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.
CAUTION
Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
AGE 16 WARNING
The Age 16 warning is located on the left-hand wheel well.
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.
23
SAFETY
4X4 (AWD) CAUTION
CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
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.
“NO PASSENGER” WARNING
WARNING
NEVER ride as a passenger. Passengers can cause a loss of control, resulting
in SEVERE INJURY or DEATH.
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: 7.0 psi (48.3 kPa)
– Rear: 7.0 psi (48.3 kPa)
• Maximum weight capacity: 575 lbs. (261 kg)
• Lug nut torque values: 75 ft-lbs. (102 Nm)
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 50 lbs. (22
kg) and/or front cargo loads are above 25 lbs. (11 kg).
NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs.
(91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
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 120 lbs. (54 kg) Rear 240 lbs. (109 kg)
24
SAFETY
DISCRETIONARY WARNING
WARNING
• Never operate this ATV on HILLS steeper than 25
degrees 25°. 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.
HITCH CAPACITY LABEL
The Hitch Capacity label
o
is located on the hitch bracket.
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL
GROUND
850 LBS. (386 KG) UP TO 15°
GRADE
HITCH MAX. VERTICAL WEIGHT:
150 LBS. (68 KG)
25
SAFETY
26
FEATURES AND CONTROLS
SWITCHES
q
Headlight Switch
r
Ignition Switch
w
Mode/Reverse Override Switch
t
4x4 Switch
e
Engine Stop Switch
IGNITION SWITCH/LIGHT SWITCH
Use the ignition switch to start the engine. The key can be removed from the
switch when it is in the OFF position.
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.
27
FEATURES AND CONTROLS
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 depress the override button
e
. The reverse override button also
acts as a MODE button when held down
for approximately one half second. The
override button will not function as a
MODE button if the transmission is in
reverse.
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.
28
FEATURES AND CONTROLS
4X4 SWITCH (IF EQUIPPED)
The drive mode switch
t
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).
See page 36 for drive mode (AWD)
operating instructions.
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
y
. The throttle lever is spring
loaded. Engine speed returns to idle
when the lever is released. This ATV is
equipped with a throttle release switch,
which is designed to reduce the risk of a
frozen or stuck throttle.
29
FEATURES AND CONTROLS
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.
30
FEATURES AND CONTROLS
PARKING BRAKE
LOCKING THE 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.
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.
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.
31
FEATURES AND CONTROLS
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.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake
fade and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master cylinder before each ride.
1. Position the 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.
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 7 in-lbs (.8 Nm).
32
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.
33
FEATURES AND CONTROLS
AUTOMATIC TRANSMISSION GEAR SELECTOR
The transmission gear selector
q
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.
BELT LIFE
To extend belt life, use low forward gear when pulling a heavy load at less than
seven miles per hour for extended periods and when operating uphill at a slow
speed.
FUEL CAP
NOTICE
Never use fuel blends with more than 10% ethanol. Engine damage could
occur.
Always refuel with the engine stopped,
and outdoors or in a well ventilated
area. Refuel on a level surface.
Remove the fuel tank cap
q
and add
fuel. 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%, such as E-85 fuel.
The fuel tank is designed to allow for
the normal expansion of fuel. Do not
overfill. Do not fill the tank neck.
34
FEATURES AND CONTROLS
FRONT COMPARTMENT
To gain access to the front
compartment, release the front rack
latches
q
and remove the rack. To
reinstall the rack, hold the rack as
shown in the illustration. Position the
front edge in the tabs, then push the
rack downward and secure the
latches.
Access the following components in the front compartment:
• Radiator cap
• Brake fluid reservoir
• Battery
• Coolant recovery bottle cap
• Electrical/fuse/relay components
q
Radiator Cap
r
Battery
w
Coolant Bottle Cap
t
Brake Fluid Reservoir
e
Electrical/Fuse/Relay
35
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.
EXTREME USE BATTERY
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
POLARIS dealer can assist. Your dealer can provide any installation procedures
that may differ for an extreme use battery.
ALL WHEEL DRIVE SYSTEM
The All Wheel Drive system is controlled by the 4X4 switch.
4X4 MODE
When the switch is on 4X4, the ATV is four-wheel drive, and the 4X4 indicator
icon in the instrument cluster display will be visible.
When in 4X4, 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.
There is no limit to the length of time the vehicle may remain in 4X4. The vehicle
automatically engages 4X4 when operating in reverse if the switch is set to
either 4X4 position.
2X4 MODE
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
ENGAGING 4X4
The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the
vehicle's electronic system will not enable 4X4 until the engine RPM is below
3000. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If
the switch is turned off while the demand drive unit is moving, it will not
disengage until the rear wheels regain traction.
Engage the 4X4 switch before getting into conditions where front wheel drive
may be needed. If the rear wheels are spinning, release the throttle before
switching to 4X4.
NOTICE
Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause
severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4
while the rear wheels have traction or are at rest.
36
FEATURES AND CONTROLS
INSTRUMENT CLUSTER
q
Speedometer
w
Rider Information Center
e
Indicator Lamps
SPEEDOMETER
The speedometer displays vehicle speed in either miles per hour (MPH) or
kilometers per hour (km/h).
RIDER INFORMATION CENTER
The rider information center is located in the instrument cluster. All segments will
light up for one second at start-up. If the instrument cluster fails to illuminate, a
battery over-voltage may have occurred and the instrument cluster may have
shut off to protect the electronic speedometer. If this occurs, your POLARIS
dealer can provide proper diagnosis.
The information center is set to display standard units of measurement and a 12-
hour clock at the factory.
37
FEATURES AND CONTROLS
q
Gear Indicator This indicator displays gear shifter position.
H:
High Gear
L:
Low Gear
N:
Neutral
R:
Reverse Gear
P:
Park
–:
Gear Signal Error (or shifter between gears)
w
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.
e
Information
Display Area
This area displays odometer, trip meter, engine hour meter
and programmable service hour interval.
r
Under/Over
Voltage
This warning usually indicates that the vehicle is operating at
an RPM too low to keep the battery charged. It may also
occur when the engine is at idle and high electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher
RPM or recharge the battery to clear the warning.
t
Clock The clock displays time in a 12-hour or 24-hour format.
y
Service
Indicator
A flashing wrench symbol alerts the operator that the preset
service interval has been reached. Your dealer can provide
scheduled maintenance.
u
4x4 Indicator This indicator illuminates when the 4X4 system is engaged
(switch is on 4X4, AWD or ADC 4X4).
38
FEATURES AND CONTROLS
DISPLAY UNITS (STANDARD/METRIC)
The display can be changed to display either standard or metric units of
measurement.
The reverse override button acts as the MODE button when pressed and
released quickly. The transmission cannot be in reverse when using the override
button as a MODE button. This feature does not contain a vehicle speed lockout
function and can be used at any operating speed.
NOTE
To exit the set-up mode at any time, wait 10 seconds.The display automatically
exits and returns to the odometer display.
Standard Display Metric Display
Distance Miles Kilometers
Time 12–Hour Clock 24–Hour Clock
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON position.
4. When the display flashes the distance setting, tap the MODE button to
advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to the next
display option.
6. Repeat the procedure to change remaining display settings.
CLOCK MODE
TIP
The clock must be reset any time the battery has been disconnected or
discharged.
To set the clock time, do the following:
1. Turn the key to the ON position. Use the MODE button to toggle to the
odometer display.
2. Press and hold the MODE button until the hour segment flashes. Release
the button.
3. With the segment flashing, tap the MODE button to advance to the desired
setting.
39
FEATURES AND CONTROLS
4. Press and hold the MODE button until the next segment flashes. Release the
button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After
completing the 1-minute segment, step 4 will save the new settings and exit
the clock mode.
6. Turn the key to the OFF position.
ODOMETER MODE
The odometer records and displays the distance traveled by the vehicle.
TRIP METER MODE
The trip meter records the distance traveled by the vehicle if reset before each
trip. To reset, select the trip meter mode. Press and hold the MODE button until
the meter resets to zero. In the Rider Information Center, the trip meter display
contains a decimal point, but the odometer displays without a decimal point.
HOUR METER MODE
This mode logs the total hours the engine has been in operation.
PROGRAMMABLE SERVICE INTERVAL
When the hours of engine operation equal the programmed service interval
setting, the wrench icon will flash for 5 seconds each time the engine is started.
When this feature is enabled, it provides a convenient reminder to perform
routine maintenance. The service interval is programmed at 50 hours at the
factory.
To change the service interval, do the following:
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and hold the
MODE button to set the new service hour interval.
DIAGNOSTIC DISPLAY MODE
The EFI diagnostic display mode is for informational purposes only. Your
POLARIS dealer or qualified person can provide for all major repairs.
The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if you
want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and on and
the warning indicator is no longer active. This allows the determination of
persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
40
FEATURES AND CONTROLS
ENGINE ERROR CODES
The error screen displays only when the CHECK ENGINE light is on or when it
goes on and off during one ignition cycle. Error codes are not stored. When the
key is turned OFF, the code and message is lost, but will reappear if the fault
reoccurs after restarting the engine.
If the CHECK ENGINE light illuminates, retrieve the error codes from the display.
1. If the error codes are not displayed, use the MODE button to toggle until “Ck
ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code menu.
3. Record the three numbers displayed in the gear position, clock and odometer
displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. Your authorized POLARIS dealer can provide code details and diagnosis.
41
FEATURES AND CONTROLS
INDICATOR LAMPS
LAMP INDICATES CONDITION
Vehicle Speed When standard mode is selected, speed displays in
miles per hour.
When metric mode is selected, speed displays in
kilometers per hour.
Over
Temperature
This lamp illuminates to indicate an overheated
engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.
Electric Power
Steering (EPS)
Warning (if
equipped)
This indicator illuminates briefly when the key is
turned to the ON position. If the light remains on, the
EPS system is inoperative. See your POLARIS
dealer, or other qualified person, as soon as possible
for repair. Continued operation could result in
permanent damage to the EPS unit and increased
steering effort.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is set
to high beam.
Helmet/Seat
Belt
This lamp is a reminder to the operator to ensure all
riders are wearing helmets and seat belts before
operating. The driver’s seat belt is equipped with a
seat belt interlock. Vehicle speed will be limited to 15
MPH (24 km/h) if the seat belt is not secured.
Check Engine This indicator appears if an Electronic Fuel Injection
(EFI) related fault occurs. Do not operate the vehicle if
this warning appears. Serious engine damage could
result. Your dealer can assist.
42
FEATURES AND CONTROLS
OPERATION
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.
43
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
one month.
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.
44
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 30
page 85
Brake fluid
Ensure proper level page 33
Auxiliary brake Ensure proper operation page 33
Front suspension Inspect, lubricate if necessary
-
Rear suspension Inspect, lubricate if necessary
-
Steering Ensure free operation
-
Tires
Inspect condition and pressure page 86
Wheels/fasteners
Inspect, ensure fastener
tightness
-
Frame nuts, bolts, fasteners
Inspect, ensure tightness
-
Fuel and oil
Ensure proper levels page 113
Coolant level
Ensure proper level page 84
Coolant hoses
Inspect for leaks
-
Throttle
Ensure proper operation page 29
Indicator lights/switches Ensure operation page 42
Engine stop switch Ensure proper operation page 28
Air filter, pre-filter Inspect, clean page 92
Headlamp Check operation page 27
Brake light/taillight Check operation
-
Riding gear
Wear approved helmet,
goggles, and protective
clothing
page 11
Winch (if equipped) Inspect cable and switch page 61
45
OPERATION
SAFE OPERATION PRACTICES
1. Complete the recommended safety training before operating this vehicle.
See the Safety section 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.
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.
46
OPERATION
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.
TIP
The starter interlock will prevent the engine from starting if the transmission is
in gear and the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
TIP
Do not press the throttle while starting the engine.
5. Turn the ignition key past the ON position to engage the starter. Activate the
starter for a maximum of five seconds, releasing the key when the engine
starts.
6. If the engine does not start, return the key to the OFF position and wait five
seconds before attempting to start again. Activate the starter for another five
seconds if necessary. Repeat this procedure until the engine starts.
NOTICE
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
47
OPERATION
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.
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 parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and brakes on level
surfaces.
48
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.
DRIVING ON 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.
49
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 move the 4X4 switch to ADC 4X4 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.
50
OPERATION
DRIVING DOWNHILL
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Always move the 4X4 switch to ADC 4X4 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.
51
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
!
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.
52
OPERATION
DRIVING THROUGH WATER
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.
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.
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.
53
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.
54
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.
55
OPERATION
PARKING ON AN INCLINE
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
STOPPING THE ENGINE
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
WARNING
A rolling vehicle can cause serious injury. Always place the transmission in
PARK when stopping the engine.
56
OPERATION
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.
57
OPERATION
HAULING CARGO
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.
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.
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.
58
OPERATION
3. When operating over rough or hilly terrain, reduce speed and cargo weight to
maintain stable driving conditions.
4. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 10
MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front
cargo loads are above 100 lbs. (45 kg).
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.
MAXIMUM TOWING CAPACITIES
Do not exceed maximum towing capacities. Avoid towing on inclines.
Maximum Towed Load (Level
Ground)
1500 lbs. (680 kg)
Maximum Vertical Hitch Weight
150 lbs. (68 kg)
59
OPERATION
60
WINCH GUIDE
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 69.
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.
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.
61
WINCH GUIDE
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. Never immerse or submerse your winch in water. Your dealer can provide
service on your winch if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage to winch
components.
24. Unplug the remote control from the vehicle when the winch is not in use to
prevent inadvertent activation and use by unauthorized persons.
25. Never grease or oil the winch cable. This will cause the winch cable to collect
debris that will shorten the life of the cable.
62
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.
63
WINCH GUIDE
4. Always use the hook strap when handling the hook.
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 69.
• Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
64
WINCH GUIDE
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.
• 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.
65
WINCH GUIDE
b. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
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 69. 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.
66
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.
67
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.
68
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.
69
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.
70
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.
71
EMISSION CONTROL SYSTEMS
72
MAINTENANCE
PERIODIC MAINTENANCE CHART
Any qualified repair shop or person may maintain, replace or repair the emission
control devices or systems on your vehicle. An authorized 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 the safest, most
reliable condition. Inspection, adjustment and lubrication of important
components are explained in the periodic maintenance chart.
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, or other qualified person. Equivalent parts
may be used for emissions-related service.
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.
Vehicles subjected to heavy or severe use patterns must be inspected and
serviced more frequently.
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.
73
MAINTENANCE
MAINTENANCE INTERVAL CHART
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.
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.
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
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
74
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
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
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
75
MAINTENANCE
ITEM
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
REMARKS
HOUR-
S CALENDAR
MILES
(KM)
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
D
Toe Adjustment
-
Inspect periodically; adjust as needed
Headlight Aim
-
Adjust as needed
76
MAINTENANCE
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 78
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 81
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 82
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 83
Brake Fluid DOT 4 Brake
Fluid
— — — page 33
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.
A-Arms,
Front and
Rear
POLARIS All-
Season
Grease
Grease fittings after extreme use or if suspension becomes
squeaky.
77
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.
78
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.
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 74. 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.
79
MAINTENANCE
4. Clean the area around the drain plug
q
.
5. Place a drain pan under the crankcase.
6. Remove the drain plug
q
. 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
w
by loosening the three screws holding into
place.
10. Place shop towels beneath the oil filter
e
. Using an oil filter wrench
(available from your POLARIS dealer), turn the filter counter- clockwise to
remove it.
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 3/4 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.
80
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.
81
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.
82
MAINTENANCE
REAR GEARCASE OIL
Always check and change the rear gearcase oil at the intervals outlined in the
Periodic Maintenance Chart. See page 113 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.
83
MAINTENANCE
POWER STEERING UNIT
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.
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.
84
MAINTENANCE
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.
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.
85
MAINTENANCE
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. Grasp one side of the seat near the rear edge.
2. Pull upward abruptly to disengage the under-seat fasteners.
3. Remove the seat.
SIDE PANEL/FOOTWELL REMOVAL
Remove the seat before removing a side panel. To remove a side panel or
footwell, remove the fasteners securing it to the frame. Lift the right side panel
upward while removing it to clear the shifter knob.
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.
86
MAINTENANCE
TIRE TREAD DEPTH
Always replace tires when tread depth
is worn to 1/8” (3 mm) or less.
FRONT WHEEL HUB TIGHTENING
Front wheel bearing tightness and spindle nut retention are critical component
operations. All service must be performed by your authorized dealer or other
qualified service facility.
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.
87
MAINTENANCE
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
Aluminum Wheel Lug Nuts 75 ft-lbs (102 Nm)
Steel Wheel Lug Nuts 45 ft-lbs (61 Nm)
88
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 as shown in the illustration.
Position the stands so that the string is flush with the side of the rear tire. If
available, you may use a long straight-edge instead of string.
4.
Measure the distance from the string to the rim at the front
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.
89
MAINTENANCE
FUSE REPLACEMENT
If the engine stops or will not start, or if you experience other electrical failures, a
fuse may need replacement. Locate and correct any short 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.
SCRAMBLER® 850
SPARE
20A
FAN CKT
BKR
20A
UN-
SWITCH-
ED
10A
EFI
10A
FUEL
PUMP
10A
CHASSIS
RELAY
SPARE
20A
ACCES-
SORY
20A
DRIVE
20A
LIGHTS
20A
START
RELAY
HIGH
BEAM
RELAY
LOW
BEAM
RELAY
FUEL
PUMP
RELAY
FAN
RELAY
EFI
RELAY
SCRAMBLER® XP 1000
SPARE
20A
FAN CKT
BKR
20A
UN-
SWITCH-
ED
10A
EFI
10A
FUEL
PUMP
10A
CHASSIS
RELAY
SPARE
20A
EPS
30A
ACCES-
SORY
20A
DRIVE
20A
LIGHTS
20A
START
RELAY
EPS
RELAY
FUEL
PUMP
RELAY
FAN
RELAY
EFI
RELAY
SPARE
30A
90
MAINTENANCE
LIGHTS
HEADLIGHT BEAM INSPECTION
Poor lighting can result in reduced visibility when driving. Headlight and taillight
lenses become dirty during normal operation. Clean lights frequently and
replace burned out lamps promptly. Always make sure lights are adjusted
properly for best visibility.
The headlight beam can be adjusted slightly upward or downward. Use the
following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight 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.
91
MAINTENANCE
HEADLIGHT BEAM ADJUSTMENT
The headlight beam can be adjusted
horizontally and vertically.
Tighten or loosen one or more of the
three headlight adjustment screws
q
to adjust the beam upward or
downward or to the left or right.
HEADLAMP REPLACEMENT
If a headlight becomes damaged or inoperable, the entire headlight assembly
must be replaced.
TAILLIGHT/BRAKELIGHT LAMP REPLACEMENT
The taillight assembly is not serviceable. If the light fails to operate properly,
replace the entire taillight assembly.
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.
92
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.
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.
93
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 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 POLARIS dealer can assist.
7. Take the vehicle in for service as soon as possible, whether you succeed in
starting it or not. Your POLARIS dealer can provide the required service.
8. If water has been ingested into the PVT, follow the procedure on page 97 for
drying out the PVT.
94
MAINTENANCE
SPARK ARRESTER
WARNING
Failure to heed the following warnings while servicing the spark arrester 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.
• Wear eye protection and leather work gloves.
• Do not perform clean-out immediately after the engine has been run, as the
exhaust system becomes very hot. Serious burns could result from contact
with the exhaust components. Allow components to cool sufficiently before
proceeding.
Never operate without the spark arrester
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 7–9 ft. lbs. (10–12 Nm).
95
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.
The air temperature in the clutch cover is substantially reduced by using low
range while operating at low ground speeds. Reducing the temperature inside
96
MAINTENANCE
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.
97
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.
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.
98
MAINTENANCE
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.
POLARIS recommends maintaining battery charge by using a POLARIS Battery
Tender charger or by charging about once a month to make up for normal self-
discharge. Battery Tender can be left connected during the storage period, and
will automatically charge the battery if the voltage drops below a pre-determined
point. See the Polaris Products section for the part numbers.
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.
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 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less
until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
following guidelines via the table below.
99
MAINTENANCE
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% 12.8-13.0 volts None, check at 3 mos.
from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no charge
given, check in 3
months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
CAMBER AND CASTER
The camber and caster are non-adjustable.
FRONT/REAR SHOCK COMPRESSION
The compression damping clicker knob is located on the top of the front shock
reservoir and on the bottom of the rear shock reservoir. When the knob is turned
clockwise until it stops, the damping is in the fully closed position.
FOX SHOCKS
SETTING COMPRESSION DAMPING
Softest 20 clicks from closed
Factory
10 clicks from closed
Firmest 2 clicks from closed
1. Turn the clicker clockwise to increase compression damping.
2. Turn the clicker counter-clockwise to decrease compression damping.
100
MAINTENANCE
THROTTLE BODY/IDLE RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer or other qualified service facility
for adjustment.
THROTTLE CABLE FREEPLAY
1. Remove the four cover screws from the right handlebar control and remove
the cover.
2. With the handlebars straight ahead, place very light pressure on the throttle
lever. A gap of 2-3 mm should be visible between the throttle arm stop pin
and the throttle arm.
If adjustment is needed:
1. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and
slide it back far enough to expose the inline cable adjuster locknut.
2. Loosen the adjuster locknut.
3. Rotate the boot to turnt he adjuster until 2-3 mm of freeplay is achieved
between the stop pin and the throttle arm. While adjusting freeplay, flip the
throttle lever back and forth repeatedly.
4. Place the transmission in PARK. Lock the parking brake.
5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle
lever to ensure the idle speed settles.
6. If idle speed remains above or below the recommended setting (see
specification pages), verify the correct gap. If gap is correct and idle speed is
still not satisfactory, please see your POLARIS dealer or other qualified
service facility for service.
7. With the engine running, turn the handlebars fully to the left and right. Tap the
throttle lever at each turn, verifying that idle RPM returns to the
recommended setting. If idle speed increases, it may be necessary to
increase the gap between the stop pin and throttle arm, but do not exceed
the recommended 2-3 mm gap.
8. When adjustments are complete, tighten the locknut.
9. Squeeze the end of the rubber boot and slide it over the cable adjuster to its
original position.
10. Ensure the control cover seal is in place, then reinstall the cover and screws.
101
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 10-12 ft-lbs (14-17 Nm), then torque the rear two
bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.
CLEANING AND STORAGE
WASHING THE VEHICLE
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and 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.
102
MAINTENANCE
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.
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.
103
MAINTENANCE
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
• 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 2-3 tablespoons of engine oil. To access
the plug holes, use a section of clear 1/4” hose and a small plastic squeeze
bottle filled with the pre-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.
104
MAINTENANCE
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.
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.
105
MAINTENANCE
106
SPECIFICATIONS
SCRAMBLER 850
SCRAMBLER 850
Maximum Weight Capacity 290 lbs. (131 kg) (includes operator, cargo and
accessories)
Dry Weight 740 lbs. (335.7 kg) (XP)
750 lbs. (340.2 kg) (XP EPS)
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 25 lbs. (11.3 kg)
Rear Rack Capacity 50 lbs. (22.7 kg)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack load and tongue
weight not to exceed 240 lbs. /109 kg)
Hitch Towing Rating 1500 lbs. (680.4 kg)
Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)
Overall Length 82.5 in. (209.5 cm)
Overall Width 48 in. (122 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 53 in. (134.6 cm)
Ground Clearance 10.6 in. (27 cm)
Minimum Turning Radius 84 in. (213 cm) unloaded
Engine EHO850LE
Displacement 850 cc
Bore x Stroke 87 x 71.5
Alternator Output 475w @1200 RPM/Peak 630w
107
SPECIFICATIONS
SCRAMBLER 850
Compression Ratio 11:1
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 REA6MC / .035 in. (0.9 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable
Transmission)
Front Suspension Dual a-arm with 9.2" (23 cm) travel
Rear Suspension Progressive rate with 10.2" (26 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 26x8-14 / 7 psi (48.3 kPa)
Tires/Pressure, Rear 26x10-14 / 7 psi (48.3 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 Hi/Lo Beam on Bumper (50 watt)
Taillights LED
Instrument Cluster Digital/Analog
108
SPECIFICATIONS
CLUTCHING
ALTITUDE
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX
Meters (Feet)
0-1800
(0-6000)
23-60
PN 5142260
Purple
PN 7043805
140-240
PN 7045111
62SR PT
PN 3236444
1800-3700
(6000-12000)
23-50
PN 5632395
Purple
PN 7043805
140-240
PN 7045111
62SR PT
PN 3236444
SCRAMBLER XP 1000
SCRAMBLER XP 1000
Maximum Weight Capacity 290 lbs. (131 kg) (includes operator, cargo and
accessories)
Dry Weight 740 lbs. (335.7 kg) (XP)
750 lbs. (340.2 kg) (XP EPS)
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 Capacity 25 lbs. (11.3 kg)
Rear Rack Capacity 50 lbs. (22.7 kg)
Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack load and tongue
weight not to exceed 240 lbs. /109 kg)
Hitch Towing Rating 1500 lbs. (680.4 kg)
Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)
Overall Length 82.5 in. (209.5 cm)
Overall Width 48 in. (122 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 53 in. (134.6 cm)
Ground Clearance 10.6 in. (27 cm)
109
SPECIFICATIONS
SCRAMBLER XP 1000
Minimum Turning Radius 84 in. (213 cm) unloaded
Engine EHO952LE
Displacement 952 cc
Bore x Stroke 90.5 x 74
Alternator Output 475w @1200 RPM/Peak 630w
Compression Ratio 11:1
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 9.2" (23 cm) travel
Rear Suspension Progressive rate with 10.2" (26 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 26x8-14 / 7 psi (48.3 kPa)
Tires/Pressure, Rear 26x10-14 / 7 psi (48.3 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel
Brakes, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel
110
SPECIFICATIONS
SCRAMBLER XP 1000
Brake, Parking Hydraulic lock, all wheel
Headlight Hi/Lo Beam on Bumper (50 watt)
Taillights LED
Instrument Cluster Digital/Analog
CLUTCHING
ALTITUDE
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX
Meters (Feet)
0-1800
(0-6000)
23-62
PN 5332337
Purple
PN 7043805
140-120
PN 7044511
64-66FR
Parrallel BA
PN 3235972
1800-3700
(6000-12000)
23-58
PN 5632218
Purple
PN 7043805
140-120
PN 7044511
64-66FR
Parrallel BA
PN 3235972
111
SPECIFICATIONS
112
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
113
POLARIS PRODUCTS
114
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 Your dealer can assist.
Poor engine performance
Check for fouled plug or foreign material in gas tank or fuel lines.
Your POLARIS 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.
115
TROUBLESHOOTING
ENGINE DOESN'T TURN OVER
POSSIBLE CAUSE SOLUTION
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
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
116
TROUBLESHOOTING
POSSIBLE CAUSE SOLUTION
Mechanical failure Your authorized dealer can assist
Loose ignition
connections
Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
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
117
TROUBLESHOOTING
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
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
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. Your
dealer can assist.
118
TROUBLESHOOTING
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.
119
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
120
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.
121
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
vehicle.
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.
122
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. 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
123
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
124
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.
125
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
126
WARRANTY
128
2X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4X4 (AWD) Warning . . . . . . . . . . . . . . . . . . . 24
4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4x4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
A
Age 16 Warning . . . . . . . . . . . . . . . . . . . . . . . . 23
Age Restrictions. . . . . . . . . . . . . . . . . . . . . . . . 13
Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 104
Air Filter Installation . . . . . . . . . . . . . . . . . . . 92
All Wheel Drive System. . . . . . . . . . . . . . . 36
Automatic Transmission Gear
Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auxiliary Foot Brake . . . . . . . . . . . . . . 33, 86
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Battery Charging . . . . . . . . . . . . . . . . . . . . . . . 99
Battery Installation . . . . . . . . . . . . . . . . . . . . . 98
Battery Maintenance . . . . . . . . . . . . . . . . 104
Battery Removal. . . . . . . . . . . . . . . . . . . . . . . . 98
Battery Storage. . . . . . . . . . . . . . . . . . . . . . . . . 99
Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . 33
Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake System Break-in . . . . . . . . . . . . . . . 44
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
C
Camber and Caster. . . . . . . . . . . . . . . . . . 100
Clean the Exterior. . . . . . . . . . . . . . . . . . . . 103
Cleaning and Storage. . . . . . . . . . . . . . . 102
Clock Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Cover Warning. . . . . . . . . . . . . . . . . 24
Cold Weather Operation. . . . . . . . . . . . . . 48
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . 84
Crankcase Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Crossing Hillsides. . . . . . . . . . . . . . . . . . . . . . 16
D
Descending Hills Improperly . . . . . . . . 16
Diagnostic Display Mode. . . . . . . . . . . . . 40
Digital/Analog Gauge . . . . . . . . . . . . . . . . . 37
Discretionary Warning . . . . . . . . . . . . . . . . 25
Display Units (Standard/Metric . . . . . 39
Drive Belt Wear/Burn. . . . . . . . . . . . . . . . . 115
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . 55
Driving on a Sidehill (Sidehilling) . . . 52
Driving on Slippery Surfaces . . . . . . . . 49
Driving Over Obstacles . . . . . . . . . . . . . . . 54
Driving Through Water
. . . . . . . . . . . . . . . . 53
Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
E
Electromagnetic Interference . . . . . . . 71
Electronic Power Steering (EPS). . . 36
Emissions Limited Warranty. . . . . . . 124
Engaging 4X4. . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine and Drivetrain Break-in . . . . . 44
Engine Backfires . . . . . . . . . . . . . . . . . . . . . . 116
Engine Doesn't Turn Over . . . . . . . . . . 116
Engine Error Codes . . . . . . . . . . . . . . . . . . . 41
Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Engine Pings or Knocks . . . . . . . . . . . . . 117
Engine Runs Irregularly, Stalls
or Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Engine Stop Switch. . . . . . . . . . . . . . . . . . . . 28
Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . 56
Engine Stops or Loses Power . . . . . 117
Engine Turns Over, Fails to
Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
European Vibration and Noise . . . . . . . . 9
Exhaust Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Exported Products . . . . . . . . . . . . . . . . . . . 123
Exposure to Exhaust . . . . . . . . . . . . . . . . . . 14
Extreme Use Battery . . . . . . . . . . . . . . . . . . 36
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F
Failure to Inspect Before
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
129
Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Fluid Part Numbers . . . . . . . . . . . . . . . . . . . 113
Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 104
Front Compartment. . . . . . . . . . . . . . . . . . . . 35
Front Gearcase (Demand
Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Front Wheel Hub Tightening . . . . . . . . 87
Front/Rear Shock
Compression . . . . . . . . . . . . . . . . . . . . . . . . 100
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . 103
Fuse Replacement. . . . . . . . . . . . . . . . . . . . . 90
G
General Warning . . . . . . . . . . . . . . . . . . . . . . . 23
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
H
Hand Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Handling Gasoline . . . . . . . . . . . . . . . . . . . . . 14
Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Headlamp Replacement. . . . . . . . . . . . . . 92
Headlight Beam Adjustment. . . . . . . . . 92
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 28
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Beam Adjustment . . . . . . . . . . . . . . . 91
Hitch Capacity Label . . . . . . . . . . . . . . . . . . 25
Hot Exhaust Systems . . . . . . . . . . . . . . . . . 20
Hour Meter Mode . . . . . . . . . . . . . . . . . . . . . . 40
How To Obtain Warranty
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
I
Ignition Switch/Light Switch . . . . . . . . . 27
Improper Cargo Loading . . . . . . . . . . . . . 19
Improper Hill Climbing . . . . . . . . . . . . . . . . 16
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . 42
Inspect and Lubricate . . . . . . . . . . . . . . . 104
Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 37
J
Jumps and Stunts. . . . . . . . . . . . . . . . . . . . . . 16
K
Know Your Riding Area/Tread
Lightly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
L
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . 119
Lubricants / Service Products . . . . . . 113
Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . 77
M
Maintenance Interval Chart. . . . . . . . . . 74
Maintenance Log. . . . . . . . . . . . . . . . . . . . . 127
Maintenance, Periodic . . . . . . . . . . . . . . . . 73
Master Cylinder/Brake Fluid. . . . . . . . . 32
Mode/Reverse Override Switch . . . . 28
Modifications to Vehicle . . . . . . . . . . . . . . 21
N
New Operator Driving
Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
“No Passenger” Warning . . . . . . . . . . . . . 24
Noise Emission Control System . . . . 71
O
Odometer Mode . . . . . . . . . . . . . . . . . . . . . . . . 40
Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Oil and Filter Change. . . . . . . . . . . . . . . . . . 79
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Oil Recommendations . . . . . . . . . . . . . . . . 78
Operating at Excessive Speeds . . . . 15
Operating Improperly in Reverse. . . 18
Operating in Unfamiliar Terrain . . . . . 18
Operating on Frozen Bodies of
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating on Pavement . . . . . . . . . . . . . . 15
130
Operating on Public Roads . . . . . . . . . . 15
Operating on Slippery Terrain . . . . . . . 18
Operating on Steep Hills . . . . . . . . . . . . . 16
Operating Over Obstacles . . . . . . . . . . . 18
Operating Through Water . . . . . . . . . . . . 19
Operating With a Passenger . . . . . . . . 14
Operation on Public Lands in
the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
P
Parking Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parking on an Incline . . . . . . . . . . . . . . . . . . 56
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . 57
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Periodic Maintenance Chart. . . . . . . . . 73
Physical Control of the Vehicle . . . . . 15
Physical Skills. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 113
Polishing the Vehicle . . . . . . . . . . . . . . . . 103
Poor Visibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Steering Unit (Cleaning). . . . . 84
Pre-Ride Checklist. . . . . . . . . . . . . . . . . . . . . 45
Programmable Service Interval. . . . . 40
Protective Apparel . . . . . . . . . . . . . . . . . . . . . 14
PVT Break-in (Clutches/Belt) . . . . . . . 44
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
R
Rack/Box Warning . . . . . . . . . . . . . . . . . . . . . 24
Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . 85
Rear Gearcase Oil . . . . . . . . . . . . . . . . . . . . . 83
Recovery Bottle Coolant . . . . . . . . . . . . . 84
Registration, Warranty . . . . . . . . . . . . . . . 119
Reverse Override Warning/
AWD Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 23
S
Safe Operation Practices . . . . . . . . . . . . 46
Safe Riding Gear. . . . . . . . . . . . . . . . . . . . . . . 11
Safety Labels and Locations . . . . . . . . 22
Safety Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Training. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . 13
Safety, Winch Maintenance. . . . . . . . . . 70
Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Shock Loading the Winch . . . . . . . . . . . . 69
Side Panel/Footwell Removal. . . . . . . 86
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Skidding or Sliding . . . . . . . . . . . . . . . . . . . . . 19
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Spark Plug Inspection. . . . . . . . . . . . . . . . .
93
Spark Plug Recommendations . . . . . 93
Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Specifications . . . . . . . . . . . . . . . . . . . 107, 109
Speedometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stabilize the Fuel. . . . . . . . . . . . . . . . . . . . . 103
Stalling While Climbing a Hill. . . . . . . . 17
Starting the Engine . . . . . . . . . . . . . . . . . . . . 47
Steering Assembly. . . . . . . . . . . . . . . . . . . . . 84
Stopping the Engine. . . . . . . . . . . . . . . . . . . 56
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
T
Taillight/Brakelight Lamp
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Throttle Body/Idle RPM. . . . . . . . . . . . . 101
Throttle Cable Freeplay . . . . . . . . . . . . 101
Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tire Pressure/Load Warning. . . . . . . . . 24
Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . . 87
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Toe Alignment. . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . 81
Transporting the ATV. . . . . . . . . . . . . . . . 105
Trip Meter Mode . . . . . . . . . . . . . . . . . . . . . . . . 40
Turning Around on a Hill (K-
Turn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Turning Improperly. . . . . . . . . . . . . . . . . . . . . 15
U
Unauthorized Use of the Vehicle . . . 20
131
V
Vehicle Break-in Period. . . . . . . . . . . . . . . 43
Vehicle Identification Numbers . . . . . . . 9
Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . 94
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . 8
Washing the Vehicle. . . . . . . . . . . . . . . . . 102
Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . . . 94
Wheel Installation . . . . . . . . . . . . . . . . . . . . . . 88
Wheel Nut Torque Specifications. . . 88
Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . . . 87
Winch Cable Care . . . . . . . . . . . . . . . . . . . . . 68
Winch Maintenance and
Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . 70
Winch Operation . . . . . . . . . . . . . . . . . . . . . . . 63
Winch Safety Precautions . . . . . . . . . . . 61
Winch Shock Loading. . . . . . . . . . . . . . . . . 69
132
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. 9929658 Rev 01
Printed in USA
Improper vehicle use can result
in SEVERE INJURY or DEATH.
READ OWNER'S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
WARNING
NEVER operate:
• without proper ATV training or instruction.
• at speeds too fast for your skills or the conditions.
• on public roads - a collision can occur with another vehicle.
• (Type I / 1-Up ATV only) with a passenger – passengers affect balance
and steering and increase risk of losing control.
• (Type II / 2-Up ATV only) with a passenger unless passenger seat
is securely in place.
THE OPERATOR MUST 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.
• (Type II / 2-Up ATV only) reduce speed and use extra caution at all times
when carrying a passenger – dismount passenger when conditions require.
• (Type II / 2-Up ATV only) make sure passenger reads and understands
all safety labels.
NEVER
CARRY
PASSENGERS
ON A
1-UP ATV
(TYPE I)
NEVER
CARRY MORE
THAN 1
PASSENGER
ON A 2-UP
ATV (TYPE II)
NEVER
USE WITH
DRUGS OR
ALCOHOL
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR FOR
DRIVER AND
PASSENGER
NEVER
USE ON
PUBLIC
ROADS
