PMS 419
Owner's Manual
for Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Sportsman X2 550 EPS International
2014
1
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.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.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• RZR® sport vehicles
• VICTORY® motorcycles
• GEM® vehicles
Always follow the instructions and recommendations in this manual.
The manual contains instructions for minor maintenance, but
information about major repairs is outlined in the POLARIS Service
Manual and should be performed only by a factory-certified Master
Service Dealer® (MSD) technician. Please see your dealer for all of
your service needs during (and after) the warranty period.
2
POLARIS® and SPORTSMAN® are registered trademarks of POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
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.
2014 SPORTSMAN X2 550 EPS International Owner’s Manual
P/N 9924898
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls. . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Emission Control Systems . . . . . . . . . . . . . . . 84
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 137
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 141
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 142
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 148
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
4
INTRODUCTION
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.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
5
INTRODUCTION
As the operator of the vehicle, you are responsible for your personal
safety, the safety of others (including your passenger), and the
protection of our environment. Read and understand your owner's
manual, which includes valuable information about all aspects of your
vehicle, including safe operating procedures.
Ride responsibly. Know all laws and regulations concerning the
operation of this vehicle in your area.
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: _____________________________________________________________
Engine Serial Number: ____________________________________________________
Key Number: ___________________________________________________________
####
VIN
Engine Serial Number
Key
Number
6
SAFETY
Failure to follow the warnings in this manual can result in serious injury or death.
This POLARIS vehicle is not a toy and can be hazardous to operate. A collision
or rollover can occur quickly, even during routine maneuvers, if you fail to take
proper precautions.
Read and understand your owner's manual and all warnings before operating
this POLARIS vehicle.
Safety Training
Never operate this vehicle without proper instruction. Take a training
course.
For more information about safety, contact an authorized POLARIS
dealer or visit the POLARIS web site at www.polaris.com.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age.
Never allow anyone under 16 years of age to operate this vehicle.
Never allow anyone under 12 years of age to ride as a passenger on this
2-up vehicle.
WARNING
7
SAFETY
Restrictions
Towing is approved OFF-ROAD ONLY. Towing a trailer with this
vehicle on public roads is prohibited. See your POLARIS dealer about
configuring the vehicle to be certified to tow a trailer on-road.
Equipment Modifications
The warranty on your POLARIS vehicle may be terminated if any
equipment has been added, or if any modifications have been made, that
increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers and large racks may change vehicle handling. Use only
POLARIS-approved accessories. Know their function and effect on the vehicle.
8
SAFETY
Rider Safety
Read and understand all warnings,
cautions and operating procedures in
this manual and on the safety labels
before operating the vehicle.
Never operate this vehicle without
proper instruction. Take a training
course. Beginners should receive
training from a certified instructor.
Never permit others to operate the
vehicle unless they have read and
understand this manual and all
product labels, and have completed a certified safety training course.
Never allow anyone under 16 years
of age to operate this vehicle.
Never allow anyone under 12 years
of age to ride as a passenger on this
2-up vehicle.
Never carry more than one
passenger on this 2-up vehicle.
Do not carry a passenger until you
have at least two hours of driving
experience with this vehicle.
Always wear an approved helmet
that fits properly. Wear eye
protection (goggles or face shield),
gloves, boots, long sleeves and long
pants.
9
SAFETY
Rider Safety
Never consume alcohol or drugs
before or while operating this
vehicle.
Never operate at excessive speeds.
Travel and turn at speeds
appropriate for the terrain, visibility,
operating conditions and your
experience.
Never attempt jumps or other stunts.
Always inspect your vehicle before
each use to verify that it's in safe
operating condition. Follow the
inspection and maintenance
procedures outlined in this manual.
See page 51.
10
SAFETY
Rider Safety
Keep both hands on the handlebars.
Keep both feet on the footrests.
A passenger should always be
seated in the passenger seat with
both feet on the footrests and both
hands on the passenger grab handles
at all times. The passenger should
never hold on to the operator.
A passenger riding in the cargo box could fall
from the vehicle unexpectedly or may contact
moving components, both of which can result in
severe injury or death. Never allow a passenger
to ride in the cargo box.
Always travel slowly when operating
on unfamiliar terrain. Use extra
caution.
Use caution when operating on
rough, slippery or loose terrain.
11
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for turning.
See page 55.
Never turn sharply at excessive
speeds, which can lead to vehicle
overturn.
If the vehicle has been involved in an accident, always have an authorized
POLARIS dealer inspect the entire vehicle for possible damage, including (but
not limited to) brake, throttle and steering systems.
Always follow the procedures
outlined in this manual for driving on
hills. See page 59.
Never operate in TURF mode while
operating on a hill or other irregular
terrain. Always move the 4X4 switch
to ADC 4X4 before ascending or
descending a hill. See page 34.
Never operate on hills too steep for
the vehicle or for your abilities.
Practice on smaller hills before
attempting larger hills. Avoid
climbing hills steeper than 15°.
>15°
12
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for driving
downhill and for braking on hills. See
page 61.
Always descend a hill with the
transmission in forward gear. Do not
descend a hill with the transmission
in neutral.
Never operate in TURF mode while
operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill. See page 34.
Always follow the procedures
outlined in this manual for crossing
the side of a hill. See page 60.
Never attempt to turn the vehicle
around on any hill until you've
mastered (on level ground) the
turning technique outlined in this
manual. See page 62.
Always follow the procedures
outlined in this manual for braking if
you stall or roll backwards while
climbing a hill. Never back down a
hill. See page 62.
13
SAFETY
Rider Safety
Always follow the procedures
outlined in this manual for operating
over obstacles. See page 65.
Always follow the procedures
outlined in this manual for operating
on slippery or loose surfaces. Use
extra caution. Always avoid skidding
or sliding. See page 58.
Always follow the procedures
outlined in this manual for driving
through water. Never drive through
deep or fast-flowing water. See page
64.
Always follow the procedures
outlined in this manual for driving in
reverse. See page 66.
14
SAFETY
Rider Safety
Always use the size and type of tires
specified for your vehicle. Maintain
the proper tire pressure.
Never modify the vehicle through improper installation or use of accessories.
Never exceed the stated load
capacity for your vehicle. Cargo
must be properly distributed and
securely attached. Reduce speed
and follow the instructions in this
manual for carrying cargo or towing.
See pages 68-71. Allow a greater
distance for braking.
Never operate the vehicle on a
frozen body of water unless you
have independently verified that the
ice is sufficiently thick to support the
weight and moving force of the
vehicle, you and your cargo,
together with any other vehicles in
your party. Variances in snow depth
and/or water currents may result in
uneven ice thickness. Always check
with local authorities and residents to confirm ice conditions and thickness over
your entire route. Vehicle operators assume all risk associated with ice
conditions on frozen bodies of water.
Operating on paved surfaces may affect the handling and control of the vehicle
and could result in loss of control. Avoid sudden turns or swift movement of the
handlebars.
15
SAFETY
Rider Safety
Always remove the ignition key when
the vehicle is not in use to prevent
unauthorized use or accidental
starting.
Always unlock the steering before starting the engine. See page 31.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
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.
Hot components can cause serious burns and fire. Do not touch hot exhaust
system components. Always keep combustible materials away from the exhaust
system.
For more information about safety, contact an authorized
POLARIS dealer or visit the POLARIS web site at
www.polaris.com.
16
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards. A passenger (on approved models) should
wear a helmet that includes a rigid chin guard.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
17
SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding a POLARIS vehicle, always wear shatterproof goggles
or use a shatterproof helmet face shield. POLARIS recommends
wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye
wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and
protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs.
Riding pants with kneepads and a jersey with shoulder pads provide the
best protection.
18
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off,
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.
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
General
Alert
Age 16
Alert
Hill
Operation
Alert
Reverse
Override
Warning
19
SAFETY
Safety Labels and Locations
General Alert
(Multi-Lingual)
Before you operate or
ride this vehicle, read
the owner’s manual.
7174362
Reverse Override Warning/4X4 Caution
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually while in reverse.
CAUTION
Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
7175512
Hill Operation Alert
• Never operate this vehicle on HILLS steeper than 15 degrees 15°.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and
brakes gradually.
7174361
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa):
Front: 7.0 psi (48.3 kPa)
Rear: 7.0 psi (48.3 kPa)
MAXIMUM WEIGHT CAPACITY 735 lbs. (333 kg)
INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO AND ACCESSORIES.
Read Owner’s Manual for more detailed loading
information.
NEVER exceed 50 MPH (80 km/h) when rear
cargo loads are above 75 lbs. (34 kg) and/or front
cargo loads are above 37 lbs. (17 kg). NEVER
exceed 50 MPH (80 km/h) while carrying a
passenger. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above
200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
7177975
PASSENGER
UNDER
12
Tire Pressure/Load
Alert
20
SAFETY
Safety Labels and Locations
Rack Warning, Front
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum combined Front Rack and Container Load: 120 lbs. (54 kg)
7175847
Clutch Cover Alert
Clutch Cover
Alert
(under seat)
Rack
Warning
Box
Warning
Hitch
Capacity
Label
21
SAFETY
Safety Labels and Locations
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15° GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
7170509
Box Warning
WARNING
Remove flammable material
containers from box before filling.
WARNING
Passengers can be thrown off. This
can cause serious injury or death.
Never carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
7173890
22
FEATURES AND CONTROLS
Switches
Main Key Switch
Use the main key switch to start the
engine. See page 53.
End all electrical power to the
vehicle.
LIGHTS ON position turns the
headlights on.
Start the engine. The headlights are
not on in this position.
After starting the engine, release the
key switch to the POSITION LIGHTS ON
position.
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4, 2X4 or TURF
mode. See pages 32-33. The
vehicle automatically engages
4X4 when operating in reverse if
the switch is set to either 4X4
position.
Trip 1
km
mi
RPM
F
E
88
:
88
Main Key
Switch
4X4
Switch
23
FEATURES AND CONTROLS
Switches
Engine Stop Switch
The engine will not start or
run when the switch is in the
OFF position.
OFF
RUN
Push the stop switch down to
stop the engine quickly. Pull
the stop switch up to the
RUN position before
attempting to start the engine.
Both the main switch and the
engine stop switch will shut
off all electrical power to the
vehicle, including lights.
Hazard Switch
Push the hazard warning switch to cause all turn signal lights to
flash simultaneously. Use this feature to alert others of an
emergency or other situation requiring caution.
Turn Signal Switch
Push the toggle switch either left or right to activate the
corresponding turn signal light. Return the toggle to the center
position to end the signal.
Horn Switch
Press the horn switch to sound the horn.
Momentary High Beam Switch
Press this switch with your left
forefinger to activate the headlight high
beam. The lights will return to low
beam when the switch is released.
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
Override
Switch
Engine
Stop
Switch
Headlight
Switch
Horn
Switch
Hazard
Switch
Turn Signal
Switch
Momentary High-Beam
Switch
24
FEATURES AND CONTROLS
Switches
Override Switch/MODE Button
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and press the
override switch.
Pressing the override button while the throttle is open can cause loss of control,
which may result in serious injury or death. Always release the throttle before
pressing the override button.
The reverse override button also acts as a MODE button when held
down for approximately one half second. See the instrument cluster
information beginning on page 38.
Tip: The override button will not function as a MODE button if the transmission
is in reverse.
Headlight Switch
The main key switch must be on and the engine stop switch must be in
the RUN position to operate the headlight switch.
High Beam
Low Beam
25
FEATURES AND CONTROLS
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving the vehicle.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Check the lever for
proper operation before starting the engine. Check occasionally during
operation.
Do not start or operate the vehicle with sticking or improperly operating throttle
controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to
increase engine speed and
vehicle movement.
Release the lever to reduce
engine speed and vehicle
movement.
Throttle Release Switch
The throttle release switch causes the engine to stop if the throttle cable
sticks in an open position when the operator releases the throttle lever.
The throttle release switch stops the engine in the event of a throttle system
malfunction. Do not modify the throttle release switch or replace it with other
throttle mechanisms.
26
FEATURES AND CONTROLS
Brake Lever
Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
hydraulically activated disc type
brakes that are activated by only
one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
27
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in an accident. Maintain brake fluid at the recommended level. Do not
overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master
cylinder before each ride.
1. Position the vehicle on a level
surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window
on the top of the master
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 add DOT 4 brake fluid only. Do not overfill.
Master Cylinder
Indicator
Window
28
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake
lever two or three times, then
squeeze and hold.
3. Push the parking brake lock
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake
lever. It will return to its unlocked position.
Operating the vehicle while the parking brake is engaged could result in an
accident or fire. Always check to be sure the parking brake is disengaged before
operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the vehicle if leaving it parked on a hill. Another option
is to park the vehicle in a sidehill position. Never depend on the parking
brake alone if the vehicle is parked on a hill. Always block the wheels to
prevent rolling.
29
FEATURES AND CONTROLS
Auxiliary Foot Brake
Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control.
Read this owner's manual and understand the operation of all brake systems on
this vehicle. Always use caution whenever applying the brakes.
The auxiliary brake system is
intended to be used as a backup for
the main brake system. Should the
main system fail, use the auxiliary
foot brake.
The foot brake operates both front
and rear brakes. The brake is located
on the inside of the right footrest.
Press the brake pedal down with
your foot to apply the brakes.
Brake Fluid Level
Check the brake fluid level
frequently for the auxiliary brake
system. The reservoir is located
under the front storage box. See page 37.
Maintain the fluid level between the
maximum and minimum marks. Use
DOT 4 brake fluid only.
NOTICE: Do not use ADC fluid in the
brake fluid reservoir. ADC
fluid will damage the rubber
components of the brake
system.
Auxiliary
Foot Brake
Brake Fluid
Reservoir
30
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is
located on the right side of the
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.
NOTICE: Shifting gears with the engine
speed above idle or while the vehicle is moving could cause
transmission damage.
Whenever the vehicle is left unattended, always place the transmission
in PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.
Gear
Selector
31
FEATURES AND CONTROLS
Fuel Tank Cap
Remove the fuel tank cap to add fuel
to the fuel tank. Use either leaded or
unleaded gasoline with a minimum
pump octane number of 87=(R+ M/2)
octane. Do not use fuel with ethanol
content greater than 10 percent, such
as E-85 fuel.
Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.
The fuel tank is designed to allow for
the normal expansion of fuel. Do not
overfill. Do not fill the tank neck.
Steering Lock
Lock the steering to prevent
unauthorized use or theft of the
vehicle.
1. Turn the handlebars to the full
right position.
Tip: The handlebars may also be locked
in the full left position.
2. Insert the steering lock key and
turn it clockwise.
3. Remove the key. Place the
steering lock keys in a safe
place. The lock must be
replaced if the keys are lost.
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is
locked. Always unlock the steering before starting the engine.
2x4
Trip 1
km
mi
RPM
F
E
88
:
88
Fuel Tank
Cap
32
FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system is
controlled by the 4X4 switch.
ADC 4X4 Mode
When the switch is on ADC 4X4, the
ADC system allows engine braking to
all four wheels when the vehicle
descends a hill or incline. Always
move the 4X4 switch to ADC 4X4
before ascending or descending a hill.
See page 34.
4X4 Mode
When the switch is on 4X4, the
vehicle is in 4X4, and the 4X4
indicator light in the instrument
cluster will be on.
When in 4X4, the demand drive unit
will automatically engage any time
the rear wheels lose traction (in
forward or reverse). 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.
4X4 Switch
ADC 4X4
33
FEATURES AND CONTROLS
All Wheel Drive System
2X4 Mode
When the switch is on 2X4, the vehicle is in two-wheel drive at all
times.
TURF Mode
When operating in TURF mode, the inside rear wheel will rotate
independently from the outside wheel during turns. Operate in TURF
mode only as needed to protect smooth, level surfaces from tire damage.
DO NOT operate in TURF mode when climbing or descending hills,
when sidehilling, or when operating on uneven, loose, or slippery terrain
such as sand, gravel, ice, snow, obstacles, and water crossings. Always
operate in ADC 4X4 or 4X4 on these types of terrain.
Operating in TURF mode when on sloped, uneven, or loose terrain could cause
loss of control and result in serious injury or death. One rear wheel may slip and
lose traction or may lift up and grab when it touches the ground again.
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable 4X4 until the
engine RPM is below 3100. Once enabled, 4X4 remains enabled until
the 4X4 switch is turned off. If the switch is turned off while the demand
drive unit is moving, it will not disengage until the rear wheels regain
traction.
Engage the 4X4 switch before getting into conditions where front wheel
drive may be needed. If the rear wheels are spinning, release the throttle
before switching to 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may
cause severe drive shaft and gearcase damage. Always switch to
4X4 or ADC 4X4 while the rear wheels have traction or are at rest.
34
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the
following conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (24 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the
following conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle speed exceeds 15 mph (24 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
35
FEATURES AND CONTROLS
Passenger Seat
Always make sure the passenger seat lock-out is functioning properly
before operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when
operating without a passenger. Always return the seat to the 1-up
position for single-rider operation.
Never carry cargo in the rear box when operating the vehicle in the 2-up
mode with a passenger.
Seat Conversion
1. Make sure the cargo box dump latch is securely latched. See page
71.
2. Slide the seat latch levers inward to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
Passenger
Backrest
Release Locks
Operator Backrest
Latches
36
FEATURES AND CONTROLS
Passenger Seat
Seat Conversion
5. Lift the adjustment latch at the top of the passenger backrest. Raise
the backrest to the desired position. Release the latch, making sure
it locks into one of the three operating positions.
Tip: The backrest must be moved out of the lowest position before it can be
secured in the upright position. The lowest position is for seat storage only.
Do not leave the backrest in the lowest position. Always adjust the backrest
to one of the three operating positions.
6. Lower the operator backrest
to create the passenger seat.
Two retaining pins under the
seat should fit into the two
grommets on the seat base.
7. Test the passenger seat lock-
out by attempting to release
the cargo box dump latch.
See page 71. If the dump
latch releases, the seat is not
secure. Repeat the set-up
procedure. If the lock-out is
not working properly, do not
allow a passenger to ride the
vehicle. See your POLARIS
dealer for service.
8. To return the vehicle to single-rider
operation, reverse all steps. Always
lower the passenger backrest to the
lowest position before folding it
down into the cargo box. Slide the
seat latch levers outward to secure the
locks.
Passenger
Backrest
Adjustment
Latch
Locked
37
FEATURES AND CONTROLS
Front Box/Compartment
Release the front box anchor latches
and remove the box assembly to gain
access to the front compartment. To
reinstall the box, hold the box as
shown in the rack illustration.
Position the front edge in the tabs,
then push the box downward and
secure the latches.
Access the following components in
the front compartment:
• Radiator cap
• Brake fluid reservoir
• ADC fluid reservoir
• Battery
• Coolant recovery bottle cap
• Electrical/fuse/relay components
Latches
ADC Fluid
Reservoir
Brake Fluid
Reservoir
Radiator
Cap
Coolant
Bottle Cap
Electrical/Fuse/Relay
Battery
38
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage vehicle components. Wash the
vehicle by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
Digital/Analog Gauge
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH)
or kilometers per hour (km/h).
Trip 1
km
mi
RPM
FE
88
:
88
Rider
Information
Center
Speedometer
Indicator Lamps
39
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Indicator Lamps
Lamp Indicates Condition
Vehicle
Speed
When standard mode is selected, speed displays in
miles per hour.
When metric mode is selected, speed displays in
kilometers per hour.
Over
Temperature
This lamp flashes to indicate an overheated engine. If
the indicator stops flashing but remains illuminated,
the overheating condition remains, and the system
will automatically reduce engine power.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is
set to high beam.
Direction
Indicators
A direction indicator flashes when a turn signal is
active. Both indicators flash when the hazard signal is
active.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.
40
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All
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, take the vehicle to your POLARIS dealer
for proper diagnosis.
The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 43.
Trip 1
km
mi
RPM
FE
88
:
88
1
2
6
5
7
3
4
8
41
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
1. Gear Display - This area displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
2. Fuel Gauge Display - The segments of the fuel gauge show the
level of fuel in the fuel tank. When the last segment clears, a low
fuel warning is activated. All segments including the fuel icon will
flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the
fuel sensor circuit. See your dealer.
3. Information Display - This area displays odometer, trip meter,
engine hour meter, engine speed and programmable service hour
interval.
4. Active Descent Control Display - This icon displays when ADC is
active. See page 34.
5. Clock Display - The clock displays time in a 12-hour or 24-hour
format. If the engine is turned off, press the MODE button. The
time will display for 5-10 seconds. See page 43 for resetting
instructions.
6. Service Reminder Display - A flashing wrench symbol alerts the
operator that the preset service interval has been reached. The
vehicle should be brought to your dealer for scheduled
maintenance. See page 43 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 or 4X4).
8. Turf Mode Indicator - This icon displays when Turf Mode is
engaged.
42
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The reverse override button acts as the MODE button when pressed and
released quickly. The transmission cannot be in reverse when using the
override button as a MODE button. This feature does not contain a
vehicle speed lockout function and can be used at any operating speed.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric units of
measurement.
Tip: To exit the set-up mode at any time, wait 10 seconds.The display
automatically exits and returns to the odometer display.
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON
position.
4. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to
the next display option.
6. Repeat the procedure to change remaining display settings.
Standard Display Metric Display
Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock
43
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or
discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meter records the distance traveled by the vehicle if reset before
each trip. To reset, select the trip meter mode. Press and hold the MODE
button until the meter resets to zero. In the Rider Information Center, the
trip meter display contains a decimal point, but the odometer displays
without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
44
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Programmable Service Interval
When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is
programmed at 50 hours at the factory. Use the following procedure to
change the service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the
determination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
45
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Engine Error Codes
The error screen displays
only when the CHECK
ENGINE light is on or when
it goes on and off during one
ignition cycle. Error codes
are not stored in the gauge
when the key is turned off.
The code and message is
lost, but will reappear if the
fault reoccurs after
restarting the engine.
If the CHECK ENGINE
light illuminates, retrieve
the error codes from the
display. Please see your
POLARIS dealer for all major repairs.
1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code
menu.
3. Record the numbers displayed in the gear position (if any), clock
and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 46-47 for code definitions and failure descriptions. Please
see your POLARIS dealer for all major repairs.
Suspect Parameter
Number (SPN)
Error Code
Number (0-9)
Failure Mode Indicator (FMI)
46
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground:
The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load:
The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery:
The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
47
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
*Assumes unipolar configuration of stepper motor
Sportsman 550 X2 Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor
Voltage Too High 51 3
Voltage Too Low 51 4
Engine Temperature Sensor
Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0
Intake Air Temperature Sensor
Voltage Too High 105 3
Voltage Too Low 105 4
Manifold Absolute Pressure Sensor
Voltage Too High 102 3
Voltage Too Low 102 4
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4
Voltage Too High 523 3
Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5
Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
Idle Air Control Driver Circuit Grounded 520193 5
Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
48
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Sportsman X2 550 EPS Diagnostic Codes
EPS Models Only
Steering Over Current Shut Down Current Above Normal or
Grounded
520221 6
Steering Excessive Current Error Current Above Normal or
Grounded
520222 6
Steering Torque Sensor T1 Partial
Failure
T1 Shorted to Ground 520223 4
T1 Shorted to Bus 520223 3
Steering Torque Sensor T2 Partial
Failure
T2 Shorted to Ground 520224 4
T2 Shorted to Bus 520224 3
Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground 520225 4
T1 and T2 Shorted to Bus 520225 3
T1 Shorted to Ground & T2
Shorted to Bus
520225 16
T2 Shorted to Ground & T1
Shorted to Bus
520225 17
T1 and T2 are Shorted 520225 2
Steering Position Sensor P1 Partial
Failure
P1 Shorted to Ground 520226 4
P1 Shorted to Bus 520226 3
Steering Position Sensor P2 Partial
Failure
P2 Shorted to Ground 520227 4
P2 Shorted to Bus 520227 3
Steering Position Sensor Full Failure P1 and P2 Shorted to Ground 520228 4
P1 and P2 Shorted to bus 520228 3
EPAS Inverter Temperature Greater than 110 Degrees C 520229 16
Greater than 120 Degrees C 520229 0
EPAS CAN Communications
Receive Error
No RX Message for 2 Seconds 520230 9
EPAS CAN Communications
Transmit Error
No TX Message for 2 Seconds 520231 9
49
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or overturn, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
Break-In Period
The break-in period for your new POLARIS vehicle is the first 20 hours
of operation. No single action on your part is as important as following
the procedures for a proper break-in. Careful treatment of a new engine
and drive components will result in more efficient performance and
longer life for these components.
NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.
WARNING
50
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 31. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 90. Add oil if
necessary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 51.
6. Pull only light loads.
7. Change both the oil and the filter at 25 hours.
8. Check the fluid level of the transmission after the first 25 hours of
operation and every 100 hours thereafter.
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation
during the break-in period.
If a belt fails, always clean away all debris when replacing the belt.
51
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the vehicle is in safe operating
condition before operating increases the risk of an accident. Always
inspect the vehicle before each use to make sure it's in safe operating
condition.
Item Remarks Page
Passenger seat lock-out Ensure proper operation 35
Brake system/lever travel Ensure proper operation 26
105
Brake fluid Ensure proper level 27
Auxiliary brake Ensure proper operation 29
Front suspension Inspect, lubricate if necessary 89
Rear suspension Inspect, lubricate if necessary 89
Steering Ensure free operation -
Steering lock Unlock the steering; ensure free oper-
ation
31
Tires Inspect condition and pressure 108
Wheels/fasteners Inspect, ensure fastener tightness 108
109
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 31
90
Coolant level Ensure proper level 103
104
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 25
128
Switches Ensure operation 22
Engine stop switch Ensure proper operation 23
Mirrors Adjust for best side/rear vision 25
Turn signals, indicators Ensure operation 23
Air filter, pre-filter Inspect, clean 110
Headlamp Check operation, apply POLARIS
dielectric grease when lamp is
replaced
24
114
Brake light/taillight Check operation, apply POLARIS
dielectric grease when lamp is
replaced
116
Riding gear Wear approved helmet, goggles, and
protective clothing
16
ADC Fluid Ensure proper level 98
Winch (if equipped) Inspect cable and switch 72-83
52
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this
vehicle.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to
operate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights
frequently and replace burned out headlamps promptly.
5. Drive in a manner appropriate for your skills, your passenger’s
skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your
hands from the handlebars while operating, and always keep both
feet on the footrests.
6. Never consume alcohol or drugs before or while operating this
vehicle.
7. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
8. Never operate a damaged vehicle. After any overturn or accident,
have a qualified service dealer inspect the entire machine for
possible damage.
9. Never operate the vehicle on a frozen body of water unless you have
independently verified that the ice is sufficiently thick to support the
weight and moving force of the vehicle, you and your cargo,
together with any other vehicles in your party.
10. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.
11. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
53
OPERATION
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 brake is not
engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
Tip: Do not press the throttle while starting the engine.
5. Turn the ignition key past the POSITION
LIGHTS ON position to engage the starter.
Activate the starter for a maximum of five
seconds, releasing the key when the engine
starts.
6. If the engine does not start, return the key to
the OFF position and wait five seconds before
attempting to start again. Activate the starter
for another five seconds if necessary. Repeat
this procedure until the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the vehicle is used year-round, check the oil level frequently. A rising
oil level could indicate the accumulation of contaminates such as water
or excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water
accumulation increases as outside temperature decreases.
If a belt fails, always clean away all debris when replacing the belt.
54
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 16.
2. Perform the pre-ride inspection. See page 51.
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.
55
OPERATION
Turning the Vehicle
1. Before turning, activate
a turn signal to alert
others of your intentions.
Activate the left signal
before a left turn.
Activate the right signal
before a right turn.
2. Steer in the direction of
the turn, leaning your
upper body to the inside
of the turn while
supporting your weight
on the outer footrest.
Use the same leaning
technique for turning in
reverse.
3. Practice making turns at
slow speeds before
attempting to turn at faster speeds.
Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp
angles. Never turn at high speeds.
56
OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on
this 2-up vehicle. Make sure any passenger is tall enough to
comfortably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear,
including an approved helmet with a rigid chin guard. See page 16.
4. Perform the pre-ride inspection. See page 51.
5. Convert the seat for 2-up riding. See page 35. Always make sure the
passenger seat lock-out is functioning properly before carrying a
passenger.
6. Lock the parking brake.
7. Mount the vehicle from the left side. After the operator is seated, the
passenger should mount the vehicle from the left side. Always make
sure the brake is engaged to ensure the vehicle remains motionless
whenever a passenger mounts or dismounts.
8. Allow a passenger to ride only in the approved passenger seat.
9. Never carry more than one passenger.
10. Slow down. Control may be more difficult with a passenger on
board. Allow more time and distance for braking.
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a
passenger to fall from the vehicle.
57
OPERATION
Driving with a Passenger
12. Do not cross a hillside with
a passenger on board. See
page 60.
13. A passenger should always
be seated in the passenger
seat with both feet on the
footrests and both hands on
the passenger grab handles
at all times. The passenger
should never hold on to the
operator.
14. Make sure the passenger
understands the importance
of "active riding." When
hill-climbing or
performing maneuvers, a passenger should shift body weight in the
same manner in which the driver shifts body weight. For example,
the passenger should lean to the inside of a turn along with the
operator and should always lean uphill when climbing and
descending hills.
58
OPERATION
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails,
gravel, snow or ice, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
4. Be alert. Watch the trail. Avoid quick, sharp turns
5. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
Sideways
skid
Turn in
direction of
skid
59
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
2. Drive straight uphill.
3. Avoid steep hills (15° maximum).
4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill. A passenger should also shift body weight
uphill.
8. Proceed at a steady rate of speed to avoid stalling.
9. Never open the throttle suddenly or make sudden gear changes.
10. Be alert. Be prepared to take emergency action. This may include
dismounting quickly.
15° Maximum
60
OPERATION
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is
necessary, follow these precautions:
1. Slow down.
2. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.
3. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.
4. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
61
OPERATION
Driving Downhill
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
3. Always descend a hill with the transmission in forward gear. Do not
descend a hill with the transmission in neutral.
4. Slow down. Never travel down a hill at high speed.
5. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.
6. Shift body weight uphill. A passenger should also shift body weight
uphill.
7. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss
of control.
15° Maximum
62
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
63
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Never operate in TURF mode while operating on a hill or other
irregular terrain. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See page 34.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then
the operator may dismount. Dismount on the uphill side of the
vehicle, or on the left if the vehicle is pointing straight uphill. A
passenger should not remount until the vehicle returns to firm, level
ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's
pointing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill. A passenger should not remount until
the vehicle returns to firm, level ground.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
64
OPERATION
Driving Through Water
Follow these procedures when driving through water:
1. Check water depth and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Drive slowly. Avoid rocks and obstacles.
4. Avoid operating in water deeper than the bottom of the footrests. If
it's unavoidable, travel slowly, balance your weight carefully and
avoid sudden movements. Maintain a slow and steady forward
motion. Do not make sudden turns, stops or throttle changes.
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 85. The following areas need
special attention: engine oil, transmission oil, demand drive fluid and
all grease fittings
.
If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 119,
then see your dealer for service at the first opportunity.
5. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
Maximum Depth
65
OPERATION
Driving Over Obstacles
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
5. Always have a passenger dismount before operating over an
obstacle that could cause a fall from the vehicle or vehicle tipover.
66
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Be aware
that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Drive slowly. Apply the brakes lightly for stopping.
4. Avoid turning at sharp angles.
5. Never open the throttle suddenly.
6. Do not use the override switch unless additional wheel speed is
required for vehicle movement. Use with caution.
NOTICE: Excessive throttle operation while in the speed limit mode may cause
fuel to build in the exhaust, resulting in engine popping and/or engine
damage.
67
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.
68
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability. Always follow these
precautions when hauling cargo:
• Read and understand the load distribution warnings listed on the vehicle
warning labels.
• Never carry cargo in the rear box when operating the vehicle in the 2-up
mode with a passenger.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
• Never exceed the stated load capacity for this vehicle. When determining the
weight you are adding to the vehicle, include the weight of the operator,
passenger, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.
• WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as
low as possible. Carrying a high load raises the center of gravity and creates
a less stable operating condition. Reduce load weight when cargo is high.
When handling off-centered loads that cannot be centered, secure the load
and operate with extra caution. When operating over rough or hilly terrain,
reduce speed and cargo to maintain stable driving conditions.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift
and create unstable operating conditions, which could result in loss of control
of the vehicle. Always be sure that the cargo bed is lowered and latched
before moving the vehicle.
• USE EXTREME CAUTION when operating with loads extending beyond the
rack or cargo bed. Stability and maneuverability may be adversely affected,
causing the machine to overturn.
• BALANCE LOADS proportionally between the front rack and cargo bed, but
do not exceed the stated load capacity. Carrying a load on only the front rack
or cargo bed may cause an imbalanced condition and increases the
possibility of vehicle overturn.
• USE EXTREME CAUTION when applying brakes with a loaded vehicle.
Avoid terrain or situations that may require backing downhill.
• Always attach the tow load to the hitch point designated for your vehicle.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 50
MPH (80 km/h) while carrying a passenger. NEVER exceed 10 MPH (16 km/
h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads
are above 100 lbs. (45 kg).
• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when
towing loads in rough terrain, while cornering, or while ascending or
descending hills.
• TOWING is approved OFF-ROAD ONLY.
• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on
the front rack.
69
OPERATION
Hauling Cargo
Never exceed the weight
capacities specified for your
vehicle on warning labels
and in the specifications
section of this manual.
1. Cargo weight should be
mounted as low as
possible.
2. When operating over
rough or hilly terrain,
reduce speed and cargo
weight to maintain
stable driving
conditions.
3. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above
75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
4. NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
5. NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above
200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
6. Always load the cargo box with the load as far forward as possible.
7. Do not obstruct the headlight beam with cargo.
8. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
9. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
10. Slow down.
11. Make sure the cargo box dump latch is securely latched before
loading and operating. Unintentional dumping will result if weight
is placed in the rear of the box and the latch is not secured.
70
OPERATION
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY. See your POLARIS dealer
about configuring the vehicle to be certified to tow a trailer on-road.
• Do not tow any trailer on a grade steeper than 15°.
• Always attach a towed load to the hitch point. Remove the hitch from
the vehicle when not towing a trailer. If towing a load, reduce rear
box cargo weight by the amount of tongue weight.
• The combination of rear box cargo weight and tongue weight must
not exceed the rear box capacity.
• The total load (operator, passenger, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your POLARIS
warranty. Never install a hitch longer
than 10 cm. Never install automotive
accessories on your POLARIS
vehicle. Always install POLARIS-
approved (or equivalent) accessories
designed for use on this vehicle.
Do not exceed the following maximum capacities when towing. Avoid
towing on inclines.
Maximum Towing Capacities
Maximum Towed Load (Level Ground) 1500 lbs. (680 kg)
Maximum Vertical Hitch Weight 150 lbs. (68 kg)
Maximum
4" (10 cm)
71
OPERATION
Hauling Cargo
Dumping Cargo
1. Select a level site to dump the cargo box. Do not attempt to dump or
unload the vehicle while parked on an incline.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Dismount the vehicle.
5. Lower the tailgate.
If cargo weight is placed toward the rear of the cargo box, the load may dump
unexpectedly and cause serious injury. When loading cargo, always position the
weight as far forward and as low as possible.
6. Pull the cargo box release
strap upward.
7. Lift the front of the cargo
box and dump the cargo.
8. Lower the cargo box and
make sure the release latch
is secured.
9. Secure the tailgate.
Operating with the cargo box in the raised position can cause serious injury and
damage to the vehicle. The cargo box could close unexpectedly and injure the
driver. The rear tires will also catch the rear of the bed, damaging the vehicle
and creating hazardous driving conditions. Never operate this vehicle with the
cargo box in the raised position.
Cargo Box
Release Strap
72
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.
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 81.
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.
WARNING
73
WINCH GUIDE
Winch Safety Precautions
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.
B. If stacking occurs, stop winching. Follow step 15 on page 79 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.
74
WINCH GUIDE
Winch Safety Precautions
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Take your winch
to your dealer for service 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.
75
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.
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 lift-
ing 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.
WARNING
Hook Strap
76
WINCH GUIDE
Winch Operation
4. Always use the hook strap when
handling the hook.
WARNING! Never put your fingers into
the hook. This could lead to SEVERE
INJURY.
A. 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 81.
B. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent
SEVERE INJURY or DEATH in the event of failure. For your safety, always
replace POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.
C. 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.
D. 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).
E. Before operating the winch, be sure
that the safety latch on the winch
cable hook is fully seated when the
load is attached.
F. Never operate your winch with a
damaged hook or latch. Always
replace damaged parts before using
the winch.
NO YES
NO
YES
77
WINCH GUIDE
Winch Operation
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
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.
B. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
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.
78
WINCH GUIDE
Winch Operation
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 81. 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.
79
WINCH GUIDE
Winch Operation
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.
80
WINCH GUIDE
Winch Cable Care
For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your
authorized POLARIS dealer.
WARNING! Use of worn or damaged cable could lead to sudden failure and
SEVERE INJURY.
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. 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.
B. 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.
C. A winch cable made of
synthetic rope should be
inspected for signs of fraying.
Replace the cable if fraying is
observed (shown at right).
Promptly discontinue use of a
winch cable in this condition.
D. 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.
A
B
C
81
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 gener-
ates 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.
82
WINCH GUIDE
Shock Loading
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.
83
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.
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.
84
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect
compliance with governmental noise level requirements.
Spark Arrestor
Your POLARIS vehicle has a spark arrestor that was designed for on-road and off-road
operation. It is required that this spark arrestor remain installed and functional when the
vehicle is operated.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI)
system controls fuel delivery. The engine and EFI components are set at the factory for
optimal performance and are not adjustable.
Electromagnetic Interference
This spark ignition system complies with Canadian standard ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and
2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with
active or non-active implantable medical devices (such as heart monitoring or
controlling devices) should review the limitations of their device and the applicable
electromagnetic standards and directives that apply to this vehicle.
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per prEN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated
by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors,
including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
85
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe,
reliable condition. Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for replacement parts, use
genuine POLARIS parts available from your POLARIS dealer. Record
maintenance and service in the Maintenance Log beginning on page
148.
Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.
Maintenance intervals in the following chart are based upon average
riding conditions and an average vehicle speed of approximately 10
miles per hour. Vehicles subjected to severe use must be inspected and
serviced more frequently.
Severe Use Definition
• Frequent immersion in mud, water or sand
• Racing or race-style high RPM use
• Prolonged low speed, heavy load operation
• Extended idle
• Short trip cold weather operation
Pay special attention to the oil level. A rise in oil level during cold
weather can indicate contaminants collecting in the oil sump or
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 or see your dealer.
86
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a “D” could result in
component failure and lead to serious injury or death. Have an authorized
POLARIS dealer perform these services.
Maintenance Chart Key
Perform all services at whichever maintenance interval is reached first.
Symbol Description
► Perform these operations more often for vehicles subjected to severe use.
E Emission-related service.
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
Make adjustments as
needed. See Pre-Ride
Checklist on page 51.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake lever travel - -
Brake system - -
Passenger seat
lock-out
--
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
Winch (if
equipped)
- - See pages 72-83
►
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Coolant - Daily - Check level daily, change
coolant every 2 years
► ADC fluid - Daily - Check level daily, add as
needed
► Headlight/taillight - Daily - Check operation; apply
dielectric grease if replacing
lamps
87
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
►
E
Air filter,
main element
- Weekly - Inspect; replace as needed
► Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
► Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change
► Demand drive fluid
(extreme use)
25 H 1 M 250 (400) Change fluid every 25 hours
if ADC is subjected to
extreme use. See page 96.
► Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check
► Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check
► Transmission oil 25 H 1 M 250 (400) Break-in oil level check
► General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
Shift linkage 50 H 6 M 500 (800) Inspect, lubricate
D Steering 50 H 6 M 500 (800) Lubricate
► Front suspension 50 H 6 M 500 (800) Lubricate
► Rear suspension 50 H 6 M 500 (800) Lubricate
D
E
Throttle Cable/
Throttle Release
Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper
sealing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
► Radiator 50 H 6 M 1000 (1600) Inspect; clean external
surfaces
► Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks
► Oil lines and
fasteners
100 H 6 M 1000 (1600) Inspect for leaks and loose
fittings
► Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter
► Demand drive fluid
(normal use)
100 H 12 M 1000 (1600) Change fluid
► Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid
► Transmission oil 100 H 12 M 1000 (1600) Change fluid
88
MAINTENANCE
Periodic Maintenance Chart
► Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
► Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/
pipe
100 H 12 M 1000 (1600) Inspect
D
E
Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
► Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
►
D
ADC fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrestor 300 H 36 M 3000 (4800) Clean out
D
E
Valve clearance 1000 H - 10000
(16000)
Inspect; adjust
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
89
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 85. Items not listed in
the chart should be lubricated at the General Lubrication interval.
The a-arms and upper control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
Item Recommended
Lubricant
Capacity
at Fluid
Change
Fill Plug
Torque
Drain Plug
Torque
Inspection
Procedure
Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt.
(1.9 l)
--- 15-17 ft. lbs.
(20-23 Nm)
Page 90.
Transmission
Oil
AGL Gearcase
Lubricant &
Transmission
Fluid
32 oz.
(950 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 94.
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 96.
Rear
Gearcase Oil
ATV Angle Drive
Fluid (or GL5 80-
90 weight gear
lube)
6.1 oz.
(180 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 100.
Brake Fluid DOT 4 Brake
Fluid
--- --- --- Page 27.
ADC Fluid Demand Drive
Fluid
--- --- --- Page 98.
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.
Front Prop Shaft Yoke
Front
90
MAINTENANCE
Engine Oil
Oil Recommendations
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 page 141 for the part numbers of POLARIS
products.
See the table on page 89 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.
91
MAINTENANCE
Engine Oil
Oil Level
Check the oil level when the engine is cold. Never check the oil with the
engine running.
1. Position the vehicle on a level surface.
2. Access the oil dipstick and fill tube from the left side of the vehicle.
Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall and tighten the dipstick.
4. Remove the dipstick and check the oil level.
5. Add the recommended fluid as needed. Maintain the oil level in the
safe range between the FULL and ADD marks. Do not overfill.
6. Reinstall and tighten the dipstick.
Dipstick
Full Add
92
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 89 for fluid recommendations, capacities and plug
torques. Always change the oil and filter at the intervals outlined in the
Periodic Maintenance Chart beginning on page 85. Always change the
oil filter whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three
minutes.
3. Stop the engine.
4. Clean the area around the drain plug.
5. Place a drain pan under the crankcase.
6. Remove the drain plug. Allow the oil to drain completely.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to specification.
Drain Plug
to front
Filter Access
93
MAINTENANCE
Engine Oil
Oil and Filter Change
9. Place shop towels beneath the oil filter.
Using an oil filter wrench (available from
your POLARIS dealer), turn the filter
counterclockwise to remove it.
10. Using a clean dry cloth, clean the filter
sealing surface on the crankcase.
11. Lubricate the o-ring on the new filter
with a film of fresh engine oil. Check to
make sure the o-ring is in good condition.
12. Install the new filter and rotate it
clockwise by hand until the filter gasket
contacts the sealing surface, then turn it
an additional 3/4 turn.
13. Remove the dipstick. Add the proper
amount of the recommended oil. Do not
overfill.
14. Reinstall the dipstick.
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
21. Dispose of used filter and oil properly.
Oil Filter
94
MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 85. See the table
on page 89 for fluid recommendations, capacities and plug torques. See
page 141 for the part numbers of POLARIS products.
Maintain the oil level at the bottom of the fill plug hole. The fill plug is
located on the right side of the vehicle behind the footwell. The drain
plug is located on the bottom left side of the gearcase.
Oil Check
1. Remove the footwell (see
page 107).
2. Remove the fill plug. Check
the oil level.
3. Add the recommended fluid
as needed to bring the level to
the bottom of the fill hole
threads.
4. Reinstall the fill plug. Torque
to specification.
5. Reinstall the footwell.
Drain Plug
Fill Plug
Fill
Level
95
MAINTENANCE
Transmission Oil
Oil Change
1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow
the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug. Add the proper amount of the recommended
oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
8. Dispose of used oil properly.
96
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Always check and change the demand drive fluid at the intervals
outlined in the Periodic Maintenance Chart beginning on page 85. See
the table on page 89 for fluid recommendations, capacities and plug
torques.
NOTICE: Change the demand drive fluid every 25 hours if the ADC unit is
exposed to extreme use.
ADC Extreme Use Definition
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. See page 141 for the part numbers of
POLARIS products.
Maintain the fluid level at
the bottom of the fill hole
threads. See below for
capacity. The fill plug is
located on the right side of
the demand drive unit. The
drain plug is located on the
bottom right side of the
unit.
Drain Plug
Fill
Plug
Fill
Level
97
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Check
1. Position the vehicle on a level surface. Remove the fill plug. Check
the fluid level.
2. Add the recommended fluid as needed to bring the level to the
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. 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.
98
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Level
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 85.
We recommend the use of POLARIS Demand Drive Fluid for the ADC
unit. Maintain the fluid level between the minimum and maximum
marks on the reservoir. See page 141 for the part numbers of POLARIS
products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
1. Remove the front box.
2. View the fluid level in the
reservoir.
3. If the level is below the
minimum mark, remove
the cap and add the
recommended fluid.
4. Reinstall the cap.
5. Reinstall the front box.
ADC Fluid
Reservoir
99
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Change
1. Position the vehicle on a level
surface. Before performing the
fluid change, allow the vehicle
to sit for at least 30 minutes.
2. Thoroughly clean the areas
around and on the ADC
reservoir and bleeder valves
(one on each side of the
differential).
3. Remove the reservoir cap and
diaphragm assembly. Use a
shop towel or suction tool to
remove debris from the fluid
and reservoir. Debris in the
reservoir may result in
inadequate bleeding and
reduced performance of the
system.
4. Fill the reservoir to the maximum line with fresh fluid.
5. Remove the protective caps from the bleeder valves.
6. Slowly loosen one of the bleeder valve screws (turn counter-
clockwise) and allow fluid and trapped air to flow from the fitting.
Tighten the screw when clean fluid begins to flow. Repeat this step
for the remaining valve.
IMPORTANT: Close the bleeder valve screws before the reservoir fluid level
drops below the minimum fill line. Adding fluid to an empty reservoir will result in
trapped air. If the level drops below the minimum line, add fluid to the maximum
line and repeat step 6 before proceeding.
7. Torque the bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the
bleeder valve caps.
8. Add fresh ADC fluid to the reservoir until the level is between the
minimum and maximum marks. Make sure the reservoir is free of
debris.
9. Reinstall the cap securely. Clean up any drips or spills.
Bleeder
Screw
Cap
Bleeder
Valve
Screw
100
MAINTENANCE
Rear Gearcase Oil
Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 85. See the table
on page 89 for fluid recommendations, capacities and plug torques. See
page 141 for the part numbers of POLARIS products.
The fill plug is located on the
rear of the gearcase. The drain
plug is located on the bottom
of the gearcase.
Maintain the fluid level at the
bottom of the fill hole threads.
Do not overfill.
Oil Check
1. Position the vehicle on a
level surface.
2. Remove the fill plug.
Check the oil level.
3. Add the recommended oil
as needed to bring the
level to the bottom of the
fill hole threads. Do not overfill.
4. Reinstall the fill plug. Torque to specification.
Drain Plug
Fill Plug
Fill
Level
101
MAINTENANCE
Rear Gearcase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque
to specification.
5. Remove the fill plug. Add the proper amount of the recommended
oil. Do not overfill.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
102
MAINTENANCE
Cooling System
The engine coolant level is controlled, or maintained, by the recovery
system. The recovery system components are the recovery bottle, the
radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the
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 60/40 premix
or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. POLARIS Antifreeze is already premixed
and ready to use. Do not dilute with water. See page 141 for the part
numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.
103
MAINTENANCE
Cooling System
Recovery Bottle Coolant
The recovery bottle fluid level can be viewed from inside the front right
wheel well. Access the recovery bottle cap under the front storage
compartment.
1. View the fluid level in the bottle.
2. If the level is low, remove the front box.
3. Remove the bottle cap and add coolant as needed. Maintain the
coolant level between the minimum and maximum marks on the
bottle (when the fluid is cool).
4. Reinstall the cap.
5. Reinstall the front box.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
104
MAINTENANCE
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine,
POLARIS recommends that you drain the system completely every two
years and add a fresh mixture of antifreeze and water.
Replace the coolant any time the cooling system has been drained for
maintenance or repair. If the recovery bottle has run dry, check the level
in the radiator. Add coolant as needed.
Escaping steam can cause burns. Never remove the pressure cap while the
engine is warm or hot. Always allow the engine to cool before removing the
pressure cap.
1. Remove the front box.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant
through the radiator filler neck.
4. Reinstall the pressure cap. Use of a
non-standard pressure cap will not
allow the recovery system to
function properly. Contact your
dealer for the correct replacement
part.
5. Reinstall the front box.
Radiator
Cap
105
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. These brakes are self-
adjusting.
Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.
An over-full master cylinder may cause brake drag or brake lock-up, which could
result in serious injury or death. Maintain brake fluid at the recommended level.
Do not overfill.
The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.
1. Always keep brake fluid at an adequate
level. See page 27.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).
5. Check the security and surface condition
of the disc. Clean any grease using a
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. See page 29.
3/64" (1 mm)
106
MAINTENANCE
Toe Alignment
Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 1/4-1/2 inch (6-12 mm) toe out.
Severe injury or death can result from improper toe alignment and adjustment.
Do not attempt to adjust tie rod alignment. All tie rod adjustments should be
performed by an authorized POLARIS dealer.
1. Position the vehicle on a
level surface.
2. Place the handlebars in a
straight-ahead position.
3. Tie a length of string
between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straight-
edge instead of string.
4. Measure the distance
from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/8-1/4 inch (3-6 mm) more than the front measurement
on each side of the vehicle to obtain the recommended 1/4-1/2 inch
(6-12 mm) toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for
service.
Steering Assembly
The steering assembly of the vehicle should be checked periodically for
loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
String
Stand
2
1
107
MAINTENANCE
Seat Removal
1. Remove any cargo from the cargo
box before removing the seat.
2. Stand beside the vehicle. Pull the
cargo box release strap upward.
Lift the front of the cargo box.
3. Grasp edge of the seat near the
opposite rear corner.
4. Pull upward abruptly to
disengage the under-seat
fasteners.
5. Remove the seat.
Side Panel/Footwell Removal
1. Remove the seat before removing a side panel.
2. To remove a side panel or footwell, remove the fasteners securing it
to the frame. Lift the right side panel upward while removing it to
clear the shifter knob.
Plastic Rivet
Hex Head Screw
Plastic Rivet
Screw
108
MAINTENANCE
Tires
Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.
Refer to the specifications section beginning on page 142 for
recommended tire type, size and pressure.
Tire Tread Depth
Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.
Front Wheel Hub Tightening
Front wheel bearing tightness and spindle nut retention are critical
component operations. All service must be performed by your
authorized POLARIS dealer.
Wheel Removal
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
Do not service axle nuts that have a cotter pin installed. See your POLARIS
dealer.
5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
1/8" (3 mm)
109
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside
and rotation arrows on the tire pointing toward forward rotation (if
equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Loose nuts could cause a tire to come off during operation, which could result in
an accident or overturn. Always ensure that all nuts are torqued to specification.
Wheel Nut Torque Specifications
Check the wheel nut torques occasionally and when they've been
loosened for service.
Wheel Type Nut Type Nut Torque
Aluminum Lug Nut 75 ft. lbs. (102 Nm)
Steel Lug Nut 45 ft. lbs. (61 Nm)
Cast Aluminum
Steel
75 ft. lbs.
(102 Nm)
45 ft. lbs.
(61 Nm)
110
MAINTENANCE
Air Filter
1. Remove the seat. See page
107.
2. Remove the air box cover
strap, and remove the air box
cover.
3. Remove the filter.
4. Remove the fabric type pre-
filter from the main filter.
Wash the pre-filter in soapy
water, then rinse and let dry.
5. Reinstall the pre-filter over
the main filter. Install a new
main filter if needed.
6. Reinstall the filter into the air
box.
7. Reinstall the air box cover
and the seat.
Main
Filter
Pre-Filter
Strap
111
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. Remove the front box.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown,
install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the front box.
Fuse Box
112
MAINTENANCE
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight
approximately 25 ft. (7.6 m) from a wall. Place the transmission in
PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.
5. Tighten or loosen the three (3)
headlight screws to adjust the
beam upward or downward or
to the left or right.
2" (5 cm)
Lamp Center Height
25 ft. (7.6 m)
Adjustment
Screws
113
MAINTENANCE
Lights
Headlight Housing Replacement
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the speedometer
harnesses from the
speedometer.
3. Unplug the headlamp from
the wiring harness.
4. Use a small screwdriver to
remove the o-rings from the
headlight mounting tabs.
5. Pull the headlight housing up
to release it from the locking
tabs.
6. Carefully pull the assembly up and out of the pod.
7. Reverse the steps to install the new housing and reassemble the pod.
Front Turn Signal Replacement
If a front turn signal light becomes
inoperable, the lamps cannot be
replaced. Replace the entire signal lamp
assembly.
114
MAINTENANCE
Lights
Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.
Hot components can cause serious burns to skin. Do not service the headlamps
until they've cooled.
Headlight Lamp Replacement
When servicing a halogen
lamp, avoid touching the
lamp with bare fingers. Oil
from your skin leaves a
residue, causing a hot spot
that will shorten the life of the
lamp. If fingers do touch a
lamp, clean it with denatured
alcohol.
1. Remove the five (5)
headlight pod screws.
2. Lift the pod cover and
disconnect the
speedometer harnesses from the speedometer.
Hot components can cause burns to skin. Allow lamps to cool before servicing.
3. Unplug the headlamp from the wiring harness. Be sure to pull on the
connector, not on the wiring.
4. Turn the lamp counterclockwise to remove it.
5. Install the new lamp. Make sure the tab on the lamp locates properly
in the housing.
6. Reassemble the pod.
115
MAINTENANCE
Lights
Headlight/Position Light Lamp Replacement
When servicing a halogen lamp, do
not touch the lamp with bare fingers.
Oil from your skin leaves a residue,
causing a hot spot that will shorten
the life of the lamp. Hold the plastic
part of the lamp.
1. Place the transmission in PARK.
2. Open the front rack cover.
3. Remove the plug at the back of the
headlight.
4. Pull the harness plug to disconnect
it from the back of the headlight.
5. Position light: Rotate the socket to
remove it. Go to step 6.
Headlamp: Reach under the
bumper and remove the rubber
cover from the back of the
headlight. Turn the collar counter-
clockwise and carefully remove
the collar and socket.
6. Remove the lamp. Apply dielectric
grease to the socket and install a
new lamp.
7. Reverse all steps to reassemble the
headlight.
Position Light
Collar
Socket
Headlamp
116
MAINTENANCE
Lights
Taillight/Brakelight Lamp Replacement
1. Open the tailgate.
2. Remove the two screws near the
tailgate latch.
3. Grasp the entire taillight assembly
and pull it away from the vehicle.
4. Remove the harness connector
from the back of the light
assembly.
5. Turn the lamp counterclockwise to
remove it.
6. Apply dielectric grease to the
socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
Screws
Lamp
117
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 142 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.
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 118.
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Using the special wrench provided in the tool pouch, rotate the
spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to
specification.
Plug Condition Torque Specification
New Spark Plug 9-11 ft. lbs.
(12-15 Nm)
Previously Installed Spark Plug 17-20 ft. lbs.
(23-27 Nm)
118
MAINTENANCE
Spark Plugs
Spark Plug Inspection
Normal Spark Plug
The normal insulator tip is gray, tan or light brown. There will be few
combustion deposits. The electrodes are not burned or eroded. This
indicates the proper type and heat range for the engine and the service.
The tip should not be flaky and white. A white insulator tip indicates
overheating, caused by use of an improper spark plug or incorrect fuel.
Wet Fouled Spark Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil, use
of non-recommended oil or incorrect throttle body adjustments.
119
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if
the machine is not thoroughly inspected. Take the vehicle to your dealer
before starting the engine. If it's impossible to take your vehicle to a
dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the
footrests.
2. Check the air box. If water is present, dry the air box and replace the
filter with a new filter.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying
procedure.
NOTICE: Serious damage can occur after immersion if fluids are not changed
promptly. See your dealer as recommended
.
7. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not.
8. If water has been ingested into the PVT, follow the procedure on
page 123 for drying out the PVT.
120
MAINTENANCE
Spark Arrestor
Failure to heed the following warnings while servicing the spark arrestor could
result in serious injury or death. Never run the engine in an enclosed area.
Remove any combustible materials from the area. Wear eye protection and
leather work gloves. Do not stand behind or in front of the vehicle while purging.
Never go under the vehicle while it's inclined.
The exhaust system can get extremely hot. Do not perform service on the spark
arrestor while the system is hot. Allow components to cool sufficiently before
proceeding.
Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe/muffler.
1. Remove the arrestor clean-
out plug from the bottom of
the muffler.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and
release the throttle lever
several times to purge
carbon from the system.
5. If carbon comes out of the
exhaust, cover or plug the
exhaust outlet(s). Wear
protective gloves.
6. Lightly tap on the exhaust pipe with a rubber mallet while repeating
step 4.
7. If particles are still suspected to be in the muffler, elevate the rear of
the vehicle one foot (30 cm) higher than the front. Block the wheels.
8. Place the transmission in PARK. Lock the parking brake. Repeat
steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor plug and remove the exhaust outlet cover or
plug.
WARNING
Clean-Out
Plug
121
MAINTENANCE
PVT System
Failure to comply with the instructions in this warning can result in severe injury
or death.
Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has been
precision balanced. Any modification will cause the system to be out of balance,
creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. Always look for
and remove debris inside and around the clutch and vent system when
replacing the belt.
• See your dealer as outlined in the owner's manual.
• This PVT system is intended for use on POLARIS products only. Do not
install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
WARNING
122
MAINTENANCE
PVT System
The basic operation of the POLARIS PVT system is dependent on
engine speed and vehicle torque requirements. As engine speed
increases, the force exerted on the movable drive sheave by the
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.
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 the clutch cover greatly extends the life of the PVT
components (belt, cover, etc.).
123
MAINTENANCE
PVT System
When To Use Low Range and High Range
The air temperature in the clutch cover is substantially reduced by using
low range while operating at low ground speeds. Reducing the
temperature inside the clutch cover greatly extends the life of the PVT
components (belt, cover, etc.).
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before
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 10 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the
transmission to the lowest available range.
6. Test for belt slippage. If the belt slips, repeat the process.
7. Take the vehicle to your dealer for service as soon as possible.
Condition Range to Use
Operating at speeds less than 7 MPH (11 km/h) Low
Towing heavy loads Low
Operating in rough terrain (swamps, mountains, etc.) Low
Operating at speeds greater than 7 MPH (11 km/h) High
124
MAINTENANCE
Battery
Improperly connecting or disconnecting battery cables can result in an explosion
and cause serious injury or death. When removing the battery, always
disconnect the negative (black) cable first. When reinstalling the battery, always
connect the negative (black) cable last.
Your vehicle is equipped with a sealed battery, which requires little
maintenance. POLARIS does not recommend using a conventional
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. Remove the front box.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. Lift the battery out of the vehicle.
WARNING
125
MAINTENANCE
Battery
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 battery charging instructions on page 126
before installing the battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
8. Install the front box.
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 141 for the
part numbers of POLARIS products.
126
MAINTENANCE
Battery
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.
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very warm
to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger
manufacturer's instructions for recharging. When using a constant
current charger, use the guidelines on the next page for recharging.
127
MAINTENANCE
Battery
Battery Charging
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
128
MAINTENANCE
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your POLARIS dealer for adjustment.
Throttle Cable Freeplay
1. Remove the four cover
screws from the right
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 in-line cable
adjuster locknut.
2. Loosen the adjuster
locknut.
3. Rotate the boot to turn the
adjuster until 2-3 mm of
freeplay is achieved
between the stop pin and
the throttle arm. While
adjusting freeplay, flip the
throttle lever back and
forth repeatedly.
(continued on next page)
2-3 mm Gap
Throttle
Arm
Arm Stop Pin
Lock
Nut
Adjuster
Boot
Cable
Adjuster
129
MAINTENANCE
Throttle Cable Freeplay
4. Place the transmission in PARK. Lock the parking brake.
5. Start the engine and allow the idle to stabilize. If necessary, tap the
throttle lever to ensure the idle speed settles.
6. If idle speed remains above or below the recommended setting (see
specification pages), verify the correct gap. If gap is correct and idle
speed is still not satisfactory, please see your POLARIS dealer for
service.
7. With the engine running, turn the handlebars fully to the left and
right. Tap the throttle lever at each turn, verifying that idle RPM
returns to the recommended setting. If idle speed increases, it may
be necessary to increase the gap between the stop pin and throttle
arm, but do not exceed the recommended 2-3 mm gap.
8. When adjustments are complete, tighten the locknut.
9. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.
10. Ensure the control cover seal is in place, then reinstall the cover and
screws.
130
MAINTENANCE
Handlebars
The handlebars can be adjusted for rider preference.
Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control and serious injury or death. Follow the adjustment
procedures exactly, or see your POLARIS dealer for service.
1. Remove the upper headlight
pod.
2. Loosen the four handlebar
bolts.
3. Adjust the handlebar to the
desired height. Be sure the
handlebars do not contact the
gas tank or any other part of
the machine when turned fully
to the left or right.
4. Torque the front two bolts to
10-12 ft. lbs. (14-17 Nm), then
torque the rear two bolts. A
gap of up to 1/8" (3 mm) will
remain at the rear of the clamp
blocks.
Handlebar
Bolts
131
MAINTENANCE
Camber and Caster
The camber and caster are non-adjustable.
Front and Rear Springs
The front and rear shock absorber
springs are adjusted by rotating the
adjuster either clockwise or
counterclockwise to increase or
decrease spring tension. Accessory
springs are available through your
POLARIS dealer.
Adjuster
132
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always secure the seat in the 1-up position to prevent loss during
transporting.
5. Secure the fuel cap and oil cap.
6. Always tie the frame of the vehicle to the transporting unit securely
with suitable straps or rope. Do not attach tie straps to the front A-
arm bolt pockets.
7. Remove the key to prevent loss during transporting.
Accessories
Auxiliary power outlets provide 12-volt power for operating
accessories. Accessory outlets are available for all models. POLARIS
also has a wide range of additional accessories available for your
vehicle. Always install accessories that are approved by POLARIS for
your vehicle. Please see your POLARIS dealer.
133
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
Keeping your POLARIS vehicle clean will not only improve its
appearance but it can also extend the life of various components.
NOTICE: High water pressure may damage components. POLARIS
recommends washing the vehicle by hand or with a garden hose,
using mild soap.
Certain products, including insect repellents and chemicals, will
damage plastic surfaces. Do not allow these types of products to
contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a
garden hose and a pail of mild soap and water.
1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last.
2. Rinse with clean water frequently.
3. Dry surfaces with a chamois to prevent water spots.
Washing Tips
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
134
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and labels. Avoid directing the water stream at the
following items:
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.
Polishing the Vehicle
POLARIS recommends the use of common household aerosol furniture
polish for polishing the finish on your POLARIS vehicle. Follow the
instructions on the container.
Polishing Tips
• Avoid the use of automotive products, some of which can scratch the
finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the
finish.
• Wheel bearings • Electrical components
• Radiator • Switches and controls
• Transmission seals • Fuel system components
• Cab and body panels • Labels and decals
135
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never
start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See
page 133.
Oil and Filter
Change the oil and filter. See page 92.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 85.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the
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.
136
MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. After stabilizing the fuel, 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.
2. Reinstall the spark plugs. Torque to specification.
3. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.
4. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a
protective film of fresh oil.
5. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and injectors should be completely drained of gasoline.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
110.
2. Clean the air box.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 85.
Battery Storage
See pages 125-126 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the vehicle with the tires slightly
off the ground. Be sure the storage area is well ventilated. Cover the
vehicle with a genuine POLARIS cover. Do not use plastic or coated
materials. They do not allow enough ventilation to prevent
condensation, and may promote corrosion and oxidation.
137
TROUBLESHOOTING
Drive Belt Wear/Burn
Possible Cause Solution
Driving onto a pickup or
tall trailer in high range
Use low range during loading.
Starting out going up a
steep incline
Use low range or turn around using the K-turn (see page
62).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 123.
Insufficient warm-up at
low ambient tempera-
tures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more flex-
ible and prevent belt burning.
Slow/easy clutch engage-
ment
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of control
and vehicle overturn.
Climbing over large
objects from a stopped
position
Shift the transmission to low range and carefully use fast,
brief, aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of control
and vehicle overturn.
Belt slippage from water
or snow ingestion into the
PVT system
Dry out the PVT. See page 123. Inspect clutch seals for
damage if repeated leaking occurs.
Clutch malfunction See your POLARIS dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or
fuel lines. See your dealer.
Slippage from failure to
warm up belt
Always warm up the belt by operating below 30 mph for
one mile (5 miles or more when temperature is below
freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 50.
138
TROUBLESHOOTING
Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution
Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Clogged fuel filter See your dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug(s) Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs, verify stop switch is on
Water or fuel in crankcase Immediately see your POLARIS dealer
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure See your dealer
Possible Cause Solution
Weak spark from spark plug Inspect, clean and/or replace spark
plug(s)
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Mechanical failure See your dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
Leaking exhaust components See your dealer
139
TROUBLESHOOTING
Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution
Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution
Fouled or defective spark plug(s) Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Throttle release switch malfunction See your dealer
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution
Low or contaminated fuel Add or change fuel, clean the fuel system
Kinked or plugged fuel tank vent line Inspect and replace
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your dealer
Incorrect fuel Replace with recommended fuel
Possible Rich Fuel Cause Solution
Fuel is very high octane Replace with lower octane fuel
Stopping/starting without adequate
warm-up
Allow engine to warm up before operat-
ing and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
140
TROUBLESHOOTING
Engine Stops or Loses Power
Engine Overheating
Possible Cause Solution
Out of fuel Refuel, cycle key to ON position three
times for 5 seconds each, then start
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug(s) Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Reverse speed limiter malfunction See your dealer
Throttle release switch malfunction See your dealer
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean
engine exterior, see your dealer
Possible Cause Solution
Debris lodged in screen Clean the screen.
Plugged Radiator Use a garden hose to flush any debris
from the radiator fins. NOTE: High pres-
sure washers can deform the radiator fins
and reduce cooling efficiency.
141
POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791 Fogging Oil (12 oz. Aerosol)
2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)
Gearcase / Transmission Lubricants
2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(gal./3.8 l)
2877922 Demand Drive Fluid (qt./.95 l)
2877923 Demand Drive Fluid (gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug
Coolant
2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l)
2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l)
Grease / Specialized Lubricants
2871312 Grease Gun Kit, All Season Grease
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
2876160 ATV Angle Drive Fluid (qt./.95 l)
2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l)
2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz./89 ml cartridge)
2871551 U-Joint Grease (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)
Additives / Miscellaneous
2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
2859044 POLARIS Battery Tender™ Charger
142
SPECIFICATIONS
* Based on EU Directive 76/432/EC
**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.
Sportsman X2 550 EPS
Maximum Weight Capacity 735 lbs. (333 kg) (includes operator, passenger,
cargo, accessories)
Dry Weight 813 lbs. (368.8 kg)
Fuel Capacity 5.25 gal. (20 l)
Engine Oil Capacity 2 qts. (1.9 l)
Coolant Capacity 2 qts. (1.9 l)
Transmission Oil Capacity 32 oz. (948 ml)
Demand Drive Fluid Capacity 9.3 oz. (275 ml)
Rear Gearcase Oil Capacity 6.1 oz. (180 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Storage Box Capacity 400 lbs. (181 kg)
Hitch Tongue Weight 150 lbs. (68 kg) (Rear box capacity and tongue
weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating 1500 lbs. (680 kg) on level ground
Unbraked Trailer Towing
Capacity*
1995 lbs. (905 kg)
Overall Length 93.25 in. (237 cm)
Overall Width 47.6 in. (121 cm)
Overall Height 49.5 in. (125.7 cm)
Wheelbase 57 in. (145 cm)
Ground Clearance 11.6 in. (29.5 cm)
Minimum Turning Radius 96 in. (244 cm) unloaded
82 in. (208 cm) (in TURF mode)
Engine ES550PLE
Displacement 549.7 cc
Bore x Stroke 96.6 x 75
Alternator Output 490w @ 1350 RPM/Peak 630w
Compression Ratio 9.6:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM** 1750 +/- 50
Ignition Timing 13 +/- 3 BTDC @ 1350 RPM, Engine warm
Spark Plug / Gap NGK BKR6E / .035 in. (0.9 mm)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable Transmis-
sion)
Front Suspension Dual A-Arm with 9" (22.9 cm) travel
Rear Suspension Progressive rate with 10.25" (26 cm) travel
143
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
Sportsman X2 550 EPS
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.693:1
Drive Ratio, Front 3.818:1
Tires/Pressure, Front 26 x 8 - 14 / 7 psi (48.3 kPa)
Tires/Pressure, Rear 26 x 10 - 14 / 7 psi (48.3 kPa)
Brakes, Front/Rear Single-Control Hydraulic Disc, All-Wheel
Brake, Auxiliary Foot-Activated Hydraulic Disc, All-Wheel
Brake, Parking Hydraulic lock, all wheel
Headlight 2 Hi/Lo beam on bumper (55/60 watt)
Taillights 8.26 watts
Brake Light 27 watts
Instrument Cluster Digital/Analog
Altitude Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
23-58
PN 1322911
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
1800-3700
(6000-12000)
23-54
PN 1322914
Red/Black
PN 7043500
Red/White
PN 3235088
105-165 BA3
PN 3235092
144
WARRANTY
LIMITED WARRANTY
POLARIS Sales 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 arrestor 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,
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.
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 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; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
145
WARRANTY
LIMITATIONS OF WARRANTIES AND REMEDIES
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:
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 CONSEQUENTAL,
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.
• Wheels and tires • Finished and unfinished surfaces
• Suspension components • Carburetor/Throttle body components
• Brake components • Engine components
• Seat components • Drive belts
• Clutches and components • Hydraulic components and fluids
• Steering components • Circuit breakers/Fuses
• Batteries • Electronic components
• Light bulbs/Sealed beam lamps • Spark plugs
• Filter • Sealants
• Lubricants • Coolants
• Bushings • Bearings
146
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 From 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. 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 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. 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.
147
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.
148
MAINTENANCE LOG
Present this section of your manual to your dealer each time your vehicle is serviced.
This will provide you and future owners with an accurate log of maintenance and
services performed.
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
149
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
150
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . . . . 22
A
Accessories . . . . . . . . . . . . . . . . . . 132
Active Descent Control Fluid . . . 98-99
Active Descent Control System. . . . 34
ADC System . . . . . . . . . . . . . . . . . . 34
Age Restrictions. . . . . . . . . . . . . . . . . 6
Air Filter . . . . . . . . . . . . . . . . . . . . 110
All Wheel Drive System . . . . . . . 32-33
Auxiliary Foot Brake. . . . . . . . . . . 105
B
Battery . . . . . . . . . . . . . . . . . . 124-127
Charging . . . . . . . . . . . . . . . 126-127
Installation . . . . . . . . . . . . . . . . 125
Removal . . . . . . . . . . . . . . . . . . 124
Storage . . . . . . . . . . . . . . . . . . . 125
Belt Life. . . . . . . . . . . . . . . . . . . . . . 30
Boots . . . . . . . . . . . . . . . . . . . . . . . . 17
Box, Front . . . . . . . . . . . . . . . . . . . . 37
Box/Compartment, Front. . . . . . . . . 37
Brake Fluid, Auxiliary Foot Brake . 29
Brake Fluid, Main Brake System. . . 27
Brake Lever . . . . . . . . . . . . . . . . . . . 26
Brake, Foot . . . . . . . . . . . . . . . 29, 105
Brake, Hand Lever. . . . . . . . . . . . . 105
Brake, Parking . . . . . . . . . . . . . . . . . 28
Brakelight Lamp Replacement . . . 116
Brakes . . . . . . . . . . . . . . . . . . . . . . 105
Break-In Period . . . . . . . . . . . . . . 49-50
C
Camber Adjustment. . . . . . . . . . . . 131
Cargo . . . . . . . . . . . . . . . . . . . . . . 69-71
Cargo Loading . . . . . . . . . . . . . . . . . 68
Caster Adjustment . . . . . . . . . . . . . 131
Check Engine Indicator . . . . . . . . . . 45
C
Cleaning and Storage. . . . . . . . 133-136
Clothing . . . . . . . . . . . . . . . . . . . . . . . 17
Clutching . . . . . . . . . . . . . . . . . . . . . 143
Cold Weather Operation . . . . . . . . . . 53
Coolant Bottle . . . . . . . . . . . . . . . . . 103
Coolant, Radiator. . . . . . . . . . . . . . . 104
Cooling System . . . . . . . . . . . . 102-104
D
Demand Drive Fluid . . . . . . . . . . 96-97
Diagnostic Codes, 550. . . . . . . . . 47-48
Disengaging Active Descent Control 34
Display Units, Standard/Metric. . . . . 42
Drive Belt Wear/Burn . . . . . . . . . . . 137
Drivetrain Break-In . . . . . . . . . . . . . . 50
Driving Downhill. . . . . . . . . . . . . . . . 61
Driving in Reverse. . . . . . . . . . . . . . . 66
Driving on a Sidehill . . . . . . . . . . . . . 60
Driving on Slippery Surfaces . . . . . . 58
Driving Over Obstacles . . . . . . . . . . . 65
Driving Procedures . . . . . . . . . . . . . . 54
Driving Through Water . . . . . . . . . . . 64
Driving Uphill . . . . . . . . . . . . . . . . . . 59
Driving with a Passenger. . . . . . . 56-57
E
Electromagnetic Interference. . . . . . . 84
Engaging 4X4 . . . . . . . . . . . . . . . . . . 33
Engaging Active Descent Control. . . 34
Engine Break-In. . . . . . . . . . . . . . . . . 50
Engine Fogging . . . . . . . . . . . . . . . . 136
Engine Oil . . . . . . . . . . . . . . . . . . 90-93
Engine Stop Switch . . . . . . . . . . . . . . 23
Equipment Modifications . . . . . . . . . . 7
Error Codes, Engine . . . . . . . . . . . . . 45
European Vibration and Noise . . . . . 84
Exhaust Emission Control System . . 84
Eye Protection . . . . . . . . . . . . . . . . . . 17
151
INDEX
F
Fluid
ADC . . . . . . . . . . . . . . . . . . . . 98-99
Brake . . . . . . . . . . . . . . . . . . . . . . 27
Coolant. . . . . . . . . . . . . . . . . . . . 102
Demand Drive . . . . . . . . . . . . 96-97
Engine Oil . . . . . . . . . . . . . . . . . . 90
Rear Gearcase . . . . . . . . . . . . . . 100
Recommended Lubricants . . . . . . 89
Transmission . . . . . . . . . . . . . . . . 94
Fluid Change
ADC . . . . . . . . . . . . . . . . . . . . . . . 99
Demand Drive . . . . . . . . . . . . . . . 97
Engine Oil . . . . . . . . . . . . . . . 92-93
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission Oil . . . . . . . . . . . . . 95
Fluid Level
ADC . . . . . . . . . . . . . . . . . . . . . . . 98
Brake . . . . . . . . . . . . . . . . . . . 27, 29
Coolant Bottle . . . . . . . . . . . . . . 103
Demand Drive . . . . . . . . . . . . . . . 97
Engine Oil . . . . . . . . . . . . . . . . . . 91
Radiator . . . . . . . . . . . . . . . . . . . 104
Rear Gearcase . . . . . . . . . . . . . . 100
Transmission Oil . . . . . . . . . . . . . 94
Foot Brake, Auxiliary . . . . . . . . . . . . 29
Footwell Removal. . . . . . . . . . . . . . 107
Front Box/Compartment. . . . . . . . . . 37
Front Gearcase (Demand Drive). 96-97
Fuel Recommendations. . . . . . . . . . . 31
Fuel Safety . . . . . . . . . . . . . . . . . . . . 15
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 31
Fuse Replacement. . . . . . . . . . . . . . 111
G
Gasoline Handling . . . . . . . . . . . . . . 15
Gauge, Code Definitions. . . . . . . 46-48
Gauge, Digital/Analog . . . . . . . . 38-45
Gear Selector. . . . . . . . . . . . . . . . . . . 30
Gearcase Oil, Rear . . . . . . . . . 100-101
Gloves. . . . . . . . . . . . . . . . . . . . . . . . 17
H
Hand Brake . . . . . . . . . . . . . . . . . . . 105
Handlebar Adjustment . . . . . . . . . . 130
Hauling Cargo. . . . . . . . . . . . . . . 68-71
Hazard Switch. . . . . . . . . . . . . . . . . . 23
Headlight Housing Replacement . . 113
Headlight Lamp . . . . . . . . . . . . . . . 115
Headlight Lamp Replacement . . . . 114
Headlight Switch . . . . . . . . . . . . . . . 24
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 16
High Beam Adjustment . . . . . . . . . 112
High Beam Switch, Momentary . . . . 23
High Range Use . . . . . . . . . . . . . . . 123
Horn Switch . . . . . . . . . . . . . . . . . . . 23
Hub Tightening. . . . . . . . . . . . . . . . 108
I
Idle RPM Adjustment. . . . . . . . . . . 128
Immersion Maintenance . . . . . . . . . 119
Indicator Lamps . . . . . . . . . . . . . . . . 39
Instrument Cluster . . . . . . . . . . . 38-48
K
Key Switch . . . . . . . . . . . . . . . . . . . . 22
K-Turn . . . . . . . . . . . . . . . . . . . . 62-63
L
Lights
Front Turn Signal Replacement. 113
Headlight Housing Replacement 113
Headlight Lamp . . . . . . . . . 114-115
High Beam Adjustment . . . . . . . 112
Momentary High Beam Switch . . 23
Position Light Lamp . . . . . . . . . 115
Taillight/Brakelight . . . . . . . . . . 116
Low Range Use. . . . . . . . . . . . . . . . 123
Lubrication Guide. . . . . . . . . . . . . . . 89
152
INDEX
M
Maintenance Chart. . . . . . . . . . . . 85-88
Master Cylinder . . . . . . . . . . . . . . . . 27
Metric Display . . . . . . . . . . . . . . . . . 42
Mirrors. . . . . . . . . . . . . . . . . . . . . . . 25
MODE Button . . . . . . . . . . . . . . . . . 24
Modifications. . . . . . . . . . . . . . . . . . . 7
N
Noise Emission Control System . . . 84
O
Oil
Engine . . . . . . . . . . . . . . . . . . . 90-93
Rear Gearcase . . . . . . . . . . . 100-101
Transmission. . . . . . . . . . . . . . 94-95
Oil and Filter Change. . . . . . . . . . 92-93
Oil Change
Rear Gearcase . . . . . . . . . . . . . . 101
Transmission. . . . . . . . . . . . . . . . 95
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . . 91
Rear Gearcase . . . . . . . . . . . . . . 100
Transmission. . . . . . . . . . . . . . . . 94
Oil Recommendations . . . . . . . . . . . 90
Override Switch. . . . . . . . . . . . . . . . 24
P
Parking Brake . . . . . . . . . . . . . . . . . 28
Parking on an Incline. . . . . . . . . . . . 67
Passenger Seat . . . . . . . . . . . . . . . 35-36
Periodic Maintenance Chart . . . . 85-88
Polaris Product List . . . . . . . . . . . . 141
Polishing the Vehicle. . . . . . . . . . . 134
Position Light Lamp . . . . . . . . . . . 115
Pre-Ride Checklist. . . . . . . . . . . . . . 51
PVT Break-In. . . . . . . . . . . . . . . . . . 50
PVT Drying . . . . . . . . . . . . . . . . . . 123
PVT System. . . . . . . . . . . . . . . 121-123
R
Reverse Operation . . . . . . . . . . . . . . . 66
Rider Information Center. . . . . . . 40-45
Rider Safety. . . . . . . . . . . . . . . . . . 8-15
Riding Gear . . . . . . . . . . . . . . . . . 16-17
S
Safe Operation Practices . . . . . . . . . . 52
Safety Labels . . . . . . . . . . . . . . . . 18-21
Safety Training . . . . . . . . . . . . . . . . . . 6
Safety, Winch Maintenance. . . . . . . . 83
Seat Removal. . . . . . . . . . . . . . . . . . 107
Severe Use. . . . . . . . . . . . . . . . . . . . . 85
Shock Loading the Winch . . . . . . 81-82
Side Panel Removal. . . . . . . . . . . . . 107
Sidehilling . . . . . . . . . . . . . . . . . . . . . 60
Signal Words . . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor . . . . . . . . . . . . . . . . . 120
Spark Arrestor Requirements . . . . . . 84
Spark Plug Inspection . . . . . . . 117-118
Spark Plug Recommendations. . . . . 117
Spark Plugs . . . . . . . . . . . . . . . 117-118
Speedometer . . . . . . . . . . . . . . . . . . . 38
Spring Adjustment, Shock. . . . . . . . 131
Starting the Engine . . . . . . . . . . . . . . 53
Steering Assembly. . . . . . . . . . . . . . 106
Steering Lock. . . . . . . . . . . . . . . . . . . 31
Stop Switch . . . . . . . . . . . . . . . . . . . . 23
Storage. . . . . . . . . . . . . . . . . . . 133-136
Storage Tips. . . . . . . . . . . . . . . 135-136
Switches . . . . . . . . . . . . . . . . . . . 22-24
4X4 Switch . . . . . . . . . . . . . . . . . . 22
Engine Stop Switch. . . . . . . . . . . . 23
Hazard Switch. . . . . . . . . . . . . . . . 23
Headlight Switch . . . . . . . . . . . . . 24
Horn Switch . . . . . . . . . . . . . . . . . 23
Main Key Switch . . . . . . . . . . . . . 22
MODE Button. . . . . . . . . . . . . . . . 24
Momentary High Beam Switch . . 23
Override Switch . . . . . . . . . . . . . . 24
Turn Signal Switch . . . . . . . . . . . . 23
153
INDEX
T
Taillight Lamp Replacement . . . . . 116
Throttle Body Adjustment . . . . . . . 128
Throttle Cable Freeplay . . . . . 128-129
Throttle Lever . . . . . . . . . . . . . . . . . . 25
Tire Tread Depth. . . . . . . . . . . . . . . 108
Tires . . . . . . . . . . . . . . . . . . . . 108-109
Wheel Installation . . . . . . . . . . . 109
Wheel Nut Torque . . . . . . . . . . . 109
Wheel Removal . . . . . . . . . . . . . 108
Toe Alignment . . . . . . . . . . . . . . . . 106
Towing Capacities . . . . . . . . . . . . . . 70
Towing Loads . . . . . . . . . . . . . . . . . . 70
Training, Safety . . . . . . . . . . . . . . . . . 6
Transmission. . . . . . . . . . . . . . . . . . . 30
Transmission Oil. . . . . . . . . . . . . 94-95
Transporting the Vehicle . . . . . . . . 132
Turn Signal Switch . . . . . . . . . . . . . . 23
Turning Around on a Hill . . . . . . 62-63
Turning the Vehicle . . . . . . . . . . . . . 55
V
Vehicle Identification Numbers . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 119
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle. . . . . . . . 133-134
Wheel Installation. . . . . . . . . . . . . . 109
Wheel Nut Torque Specifications. . 109
Wheel Removal . . . . . . . . . . . . . . . 108
Winch Cable Care. . . . . . . . . . . . . . . 80
Winch Maintenance/Service Safety . 83
Winch Operation. . . . . . . . . . . . . 75-79
Winch Safety Precautions. . . . . . 72-74
Winch Shock Loading . . . . . . . . 81-82
For your nearest Polaris dealer,
visit www.polaris.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340 USA
Part No. 9924898 Rev 02
Printed in USA
*9924898 *
PMS 419
GB
D
E
F
I
FI
P
S
Before you operate or ride this vehicle, read the
owner’s manual.
Lesen Sie die Bedienungsanleitung, bevor Sie
dieses Fahrzeug bedienen oder fahren.
Antes de operar o conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel d’utilisation avant d’utiliser ou de
conduire ce véhicule.
Prima di usare o guidare il veícolo, leggere il
Manuale di istruzioni.
Lue aina käyttöohjekirja ennen tämän ajoneuvon
käyttöä tai ajamista.
Antes de utilizar ou andar neste veículo, leia o
Manual do proprietário.
Innan du hanterar eller kör detta fordon, läs
Handboken.
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