PMS 419
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
Owner's Manual
for Maintenance and Safety
2017
Scrambler
® 1000
Scrambler
® XP 1000
Scrambler
® XP 1000 Zugmachine
Sportsman
® 1000
Sportsman
® XP 1000
Sportsman
® XP 1000 Zugmachine
Sportsman
® Touring XP 1000
1
2017 Owner’s Manual
Scrambler® 1000
Scrambler® XP 1000
Sportsman® 1000
Sportsman® XP 1000
Sportsman® XP 1000 Zugmachine
Sportsman® Touring XP 1000
2
POLARIS®, SCRAMBLER® and SPORTSMAN® are trademarks of POLARIS
Industries Inc.
Copyright 2016 POLARIS Industries Inc. All information contained within this
publication is based on the latest product information at the time of publication. Due to
constant improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in
this publication. Depictions and/or procedures in this publication are intended for
reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole
or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
P/N 9927460
3
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Features and Controls. . . . . . . . . . . . . . . . . . . 27
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Emission Control Systems . . . . . . . . . . . . . . . 95
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 143
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 147
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 148
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 160
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
4
INTRODUCTION
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.
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.
• Snowmobiles • RZR® sport vehicles
• All-terrain vehicles (ATVs) • GEM® electric vehicles
• Low emission vehicles (LEVs) • VICTORY® motorcycles
• RANGER® utility vehicles • INDIAN® motorcycles
•BRUTUS® work vehicles • POLARIS POWER® generators
• SLINGSHOT® three wheel
motorcycles
• POLARIS DEFENSE® combat
vehicles
5
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.
6
INTRODUCTION
Polaris Sales Europe Sàrl
Route de I’Etraz
Business Center A5
1180 Rolle, Switzerland
Telephone +41213-218-700
DECLARATION OF CONFORMITY
January 1, 2016
Polaris Sales Europe
Sàrl declares that the vehicle(s)
listed below conform to the essential requirements
applicable to all terrain vehicles.
APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS
2006/42/EC as amended
(Machinery Directive)
EN 15997
2004/108/EC as amended
(EMC Directive)
UNECE R10
97/24/EC Chapter 8
MODEL COMMERCIAL NAME SERIAL NUMBER
A_ _SX _ 95_ _
(All combinations)
Sportsman XP 1000
Zugmachine
TAPS_ _95_G_ _ _ _ _ _ _
(All combinations)
A_ _SX _ 95_ _
(All combinations)
Sportsman 1000
Sportsman XP 1000
Sportsman Touring XP 1000
TAPS_ _95_G_ _ _ _ _ _ _
(All combinations)
A_ _SV _ 95_ _
(All combinations)
Scrambler 1000
Scrambler XP 1000
TAPS_ _95_G_ _ _ _ _ _ _
(All combinations)
7
INTRODUCTION
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: ___________________________________________________________
Engine Serial Number
Key Number
VIN
8
SAFETY
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.
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 oper-
ating 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 12 years of age to ride as a passenger on a 2-
up vehicle.
WARNING
9
SAFETY
Restrictions
Towing is approved OFF-ROAD ONLY unless your vehicle is approved
for on-road operation. 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.
10
SAFETY
Rider Safety
Serious injury or death can result if you do not follow the instructions and
procedures listed here and throughout this manual.
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 a 2-up vehicle.
Never carry a passenger on a 1-up vehicle.
Never carry more than one passenger on a 2-up
vehicle. Do not carry a passenger on a 2-up vehicle
until you have at least two hours of driving
experience with the vehicle. See page 68.
WARNING
<
16
11
SAFETY
Rider Safety
Operator and passenger must always wear an
approved helmet that fits properly. Wear eye
protection (goggles or face shield), gloves, boots,
long sleeves and long pants.
Never consume alcohol or drugs before or while
operating this vehicle.
Operating this ATV on public streets could result in a
collision with another vehicle.
Never operate an off-road vehicle on any public
street, road or highway, including dirt and gravel
roads (unless designated for off-highway use).
Zugmachine only: This vehicle is approved for
on-road operation.
12
SAFETY
Rider Safety
Always remove the ignition key when the vehicle
is not in use to prevent unauthorized use or
accidental starting.
Always wear an approved helmet that fits
properly. Wear eye protection (goggles or face
shield), gloves, boots, long sleeves and long
pants.
Never operate at excessive speeds. Travel and
turn at speeds appropriate for the terrain,
visibility, operating conditions, your skills and a
passenger’s skills.
Always use the size and type of tires specified
for your vehicle. Maintain the proper tire
pressure.
13
SAFETY
Rider Safety
Always inspect your vehicle before each use to
verify that it's in safe operating condition. See page
64. Follow the inspection and maintenance
procedures outlined in this manual.
Keep both hands on the handlebars. Keep both
feet on the footrests. A passenger should always
be seated behind the operator with both hands on
the passenger grab handles at all times. The
passenger should never hold on to the operator.
Always travel slowly when operating on unfamiliar
terrain. Use extra caution.
Always follow the procedures outlined in this
manual for turning. See page 67.
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.
14
SAFETY
Rider Safety
Never attempt jumps or other stunts.
Always follow the procedures outlined in this manual for driving on hills. See
page 74.
Always move the 4X4 switch to 4WDC before ascending or descending a hill.
Operating on excessively steep hills could cause a rollover. Never operate on
hills too steep for the ATV or for your abilities.
• Never operate a 1-up ATV on hills steeper than 25
°.
• Never operate a 2-up ATV on hills steeper than 15
°.
Always follow the procedures outlined in this
manual for driving downhill and for braking on hills.
See page 77.
Always follow the procedures outlined in this
manual for crossing the side of a hill. See page 76.
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 78.
15
SAFETY
Rider Safety
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 75.
Always follow the procedures outlined in this manual for operating over
obstacles. See page 72.
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 70.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water. See page 71.
Always follow the procedures outlined in this manual for driving in reverse. See
page 73.
16
SAFETY
Rider Safety
Gasoline is highly flammable and explosive under certain conditions.
• Use extreme caution whenever handling gasoline.
• Refuel with the engine stopped. Refuel 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.
Engine exhaust contains poisonous carbon monoxide and can cause loss of
consciousness resulting in severe injury or death. Never run an engine in an
enclosed area.
Never modify this 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. 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.
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.
Always unlock the steering before starting the engine. See page 36.
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.
17
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Always wear a helmet that meets or exceeds established safety
standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long
Sleeves
E
4
051039
0006.31
18
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.
19
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.
Replacement safety labels are provided by POLARIS at no charge. The
part number is printed on the label.
Sportsman XP 1000 Zugmachine Labels
General Alert (7181539)
Before you operate this vehicle, read the owner’s manual. Never allow anyone
under 16 years of age to operate this vehicle. Wear approved helmet, goggles,
and protective clothing. Never use alcohol or drugs before or while operating.
NEVER carry a passenger. This vehicle is approved for onroad use.
Override Alert / 4X4 (AWD) Alert (7182094)
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.
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
Hill Operation Alert (7181426)
Never operate this vehicle on HILLS steeper than 25°.
General Alert
Hill Operation Alert
Override Alert
4X4 (AWD) Alert
7182094
SPEEDO
REVERSE
OVERRIDE
7181426
<
16
<
16
7181539
20
SAFETY
Safety Labels and Locations
Sportsman XP 1000 Zugmachine Labels
Tire Pressure Alert (7183226)
FRONT 45 kPa/0.5 bar REAR 45 kPa/0.5 bar
Clutch Cover Alert (7181427)
Keep body parts away from belt.
Rack Alert (7181582)
DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or
hitch.Max. Rack Loads: Front 55 kg Rear 110 kg
7181427
55 kg 110 kg
7181582
kPa/bar
7183226
45 kPa/0.5 bar 45 kPa/0.5 bar
Rack Alert
Clutch Cover Alert
Tire Pressure Alert
21
SAFETY
Safety Labels and Locations
Scrambler XP 1000 Zugmachine Labels
General Alert (7181537)
Before you operate this vehicle, read the owner’s manual. Never allow anyone
under 16 years of age to operate this vehicle. Wear approved helmet, goggles,
and protective clothing. Never use alcohol or drugs before or while operating.
Never carry a passenger on this vehicle. Never operate the vehicle on any
public street, road or highway.
Hill Operation Alert (7181426)
Never operate this vehicle on HILLS steeper than 25
°.
SCRAMBLER Override Alert (7181544) / 4X4 (AWD) Alert (7181543)
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.
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
General Alert
7181537
<
16
<
16
7181543
Hill Operation Alert
Override Alert
22
SAFETY
Safety Labels and Locations
Scrambler XP 1000 Zugmachine Labels
SCRAMBLER Rack Alert (7181583)
DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch.
Max. Rack Loads: Front 11 kg Rear 23 kg
Clutch Cover Alert (7181427)
Keep body parts away from belt.
SCRAMBLER Tire
Pressure/Load Alert (7181589)
TIRE PRESSURE IN kPa: FRONT 35 REAR 35
MAXIMUM WEIGHT CAPACITY 131 kg
Rack Alert
Clutch Cover Alert
Tire Pressure Alert
35 kPakPa 35 kPa
< 131kg
7181589
11 kg 23 kg
7181583
7181427
23
SAFETY
Safety Labels and Locations
Scrambler and Sportsman XP 1000 Labels
General Alert (7181537)
Before you operate this vehicle, read the owner’s manual. Never allow anyone
under 16 years of age to operate this vehicle. Wear approved helmet, goggles,
and protective clothing. Never use alcohol or drugs before or while operating.
Never carry a passenger on this vehicle. Never operate the vehicle on any
public street, road or highway.
SPORTSMAN Override Alert / 4X4 (AWD) Alert (7182094)
SCRAMBLER Override Alert (7181544) / 4X4 (AWD) Alert (7181543)
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.
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
Hill Operation Alert (7181426)
Never operate this vehicle on HILLS steeper than 25
°.
7181426
General Alert
Hill Operation Alert
7181543
SPORTSMAN
Override Alert/4X4 (AWD) Alert
SCRAMBLER
Override Alert
4X4 (AWD) Alert
SPEEDO
REVERSE
OVERRIDE
7181544
7181537
<
16
<
16
7182094
SPEEDO
REVERSE
OVERRIDE
24
SAFETY
Safety Labels and Locations
Scrambler and Sportsman XP 1000 Labels
SPORTSMAN Tire Pressure/Load Alert (7181588)
TIRE PRESSURE IN kPa: FRONT 45 REAR 45
MAXIMUM WEIGHT CAPACITY 261 kg
SCRAMBLER Tire
Pressure/Load Alert (7181589)
TIRE PRESSURE IN kPa: FRONT 35 REAR 35
MAXIMUM WEIGHT CAPACITY 131 kg
SPORTSMAN Rack Alert (7181582)
DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch.
Max. Rack Loads: Front 55 kg Rear 110 kg
SCRAMBLER Rack Alert (7181583)
DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch.
Max. Rack Loads: Front 11 kg Rear 23 kg
Hitch Capacity Alert (7182175)
TRAILER MAX WEIGHT: 680 kg ON LEVEL GROUND
HITCH MAXIMUM VERTICAL WEIGHT: 68 kg
Clutch Cover Alert (7181427)
Keep body parts away from belt.
55 kg 110 kg
7181582
7181427
11 kg 23 kg
7181583
35 kPakPa 35 kPa
< 131kg
7181589
45 kPakPa 45 kPa
7181588
< 261kg
Rack Alert (Sportsman)
Hitch Capacity Alert
Clutch Cover Alert
Tire Pressure/Load Alert
(Sportsman)
Rack Alert (Scrambler)
Tire Pressure/Load Alert
(Scrambler)
680 kg
68 kg
7182175
25
SAFETY
Safety Labels and Locations
Sportsman Touring XP 1000 Labels
General Alert (7181538)
Before you operate this vehicle, read the owner’s manual. Never allow anyone
under 16 years of age to operate this vehicle. Wear approved helmet, goggles,
and protective clothing. Never use alcohol or drugs before or while operating.
Never carry more than one passenger on this vehicle. Never operate the vehicle
on any public street, road or highway.
Override Alert / 4X4 (AWD) Alert (7182094)
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.
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
Hill Operation Alert (7181536)
Never operate this vehicle on HILLS steeper than 15
°.
15°
7181536
7181538
<
16
<
16
General Alert
Hill Operation Alert
Override Alert
4X4 (AWD) Alert
7182094
SPEEDO
REVERSE
OVERRIDE
26
SAFETY
Safety Labels and Locations
Sportsman Touring XP 1000 Labels
Tire Pressure/Load Alert (7182138)
TIRE PRESSURE IN kPa: FRONT 45 REAR 45
MAXIMUM WEIGHT CAPACITY 261 kg
Clutch Cover Alert (7181427)
Keep body parts away from belt.
Rack Alert (7181582)
DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch.
Max. Rack Loads: Front 55 kg Rear 110 kg
Hitch Capacity Alert (7182175)
TRAILER MAX WEIGHT: 680 kg ON LEVEL GROUND
HITCH MAXIMUM VERTICAL WEIGHT: 68 kg
7181427
45 kPakPa 45 kPa
7182138
< 261kg
Rack Alert
Hitch Capacity Alert
Clutch Cover Alert
Tire Pressure/Load Alert
55 kg 110 kg
7181582
680 kg
68 kg
7182175
27
FEATURES AND CONTROLS
Switches
Sportsman Zugmachine Switches
Work Light Switch
The work light switch controls a light located in the pod. Use the light
when additional light is needed at the front of the vehicle, but turn the
work light off when driving the vehicle (on-road).
Fog Light Switch
Use the fog light switch to turn the fog light on or off.
4X4 Switch
See page 33.
Main Key Switch
STOP: End all electrical power to the
vehicle.
LIGHTS ON: Turn the headlights on.
The engine stop switch must be in
the RUN position.
PARKING LIGHTS ON: After
starting the engine, release the key
switch to this position. The parking lights and taillights are on in this
position.
START: Start the engine. The headlights are not on in this position. See
page 65 for starting procedures.
Left Handlebar
Controls
(see page 28)
Work Light
Switch
Fog Light
Switch
Main Key
Switch
4X4
Switch
STOP
PARKING
LIGHTS ON
LIGHTS ON START
28
FEATURES AND CONTROLS
Switches
Sportsman Zugmachine Switches
Engine Stop Switch
The engine will not start or run when the
switch is in the OFF position.
OFF
RUN
Headlight and Momentary High Beam
Switch
The lights do not operate unless the main
key switch is on and the engine stop switch
is in the RUN position.
High Beam
Low Beam
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.
Turn Signal Switch
Push the toggle switch either left or right to activate the
corresponding turn signal light. The indicator on the pod will also
flash. Return the toggle to the center position to end the signal.
Horn Switch
Press the horn switch to sound the horn.
Hazard Warning 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.
Override Switch
See page 33.
Override
Switch
Engine
Stop
Switch
Headlight and
Momentary
High Beam
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
29
FEATURES AND CONTROLS
Switches
Scrambler Zugmachine Switches
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.
Winch Switch
See page 84 for winch information.
Fog Light Switch
Use the fog light switch to turn the fog light on or off.
Mode/Reverse Override Switch
Press the switch to toggle through the speedometer display modes
(except in reverse). See page 45. To gain additional power while
operating in reverse, press the override switch before opening the
throttle. This will cancel the reverse speed limit function.
The reverse override switch also acts as a MODE switch when held
down for approximately one half second. See the instrument cluster
information beginning on page 45.
Tip: The override switch will not function as a MODE switch if the transmission
is in reverse.
Activating the override switch while the throttle is open can cause loss of control.
Do not activate the override switch while the throttle is open.
Fog Light Switch
Main Key Switch
30
FEATURES AND CONTROLS
Switches
Main Key Switch
STOP: End all electrical power to the
vehicle.
LIGHTS ON: Turn the headlights on.
The engine stop switch must be in
the RUN position.
PARKING LIGHTS ON: After
starting the engine, release the key
switch to this position. The parking
lights and taillights are on in this position.
START: Start the engine. The headlights are not on in this position. See
page 65 for starting procedures.
Do not attach a large key fob or key ring to the main switch. It may contact the
gas tank cap when turning, causing an interruption to the electrical system and
an unexpected engine shut-down during operation. This could result in serious
injury or death.
Engine Stop Switch
The engine will not start or run when the
switch is in the OFF position.
OFF (STOP)
RUN
Light Switch (High/Low Beam)
Use the light switch to change the
headlights from high beam to low beam.
High Beam
Low Beam
STOP
PARKING
LIGHTS ON
LIGHTS ON
START
Override
Switch
Engine
Stop
Switch
Light
Switch
Horn
Switch
Hazard
Switch
Turn
Signal
Switch
31
FEATURES AND CONTROLS
Switches
Work Light Switch (if equipped)
The work light switch controls a light located in the pod. Use the light
when additional light is needed at the front of the vehicle, but turn the
work light off when driving the vehicle (on-road).
Turn Signal Switch
Push the toggle switch either left or right to activate the
corresponding turn signal light. The indicator in the gauge will also
flash. Return the toggle to the center position and push it inward to end
the signal.
Hazard Warning 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.
Horn Switch
Press the horn switch to sound the horn.
4X4 Switch
Use the 4X4 switch to engage
4WDC (if equipped), 4X4 or
2X4. The vehicle automati-
cally engages 4X4 when oper-
ating in reverse if the 4X4
switch is set to either 4X4
position.
4X4
Switch
32
FEATURES AND CONTROLS
Switches
Scrambler/Sportsman Switches
Headlight Switch (SPORTSMAN)
Use the headlight switch to change the lights between high beam and
low beam.
Main Key Switch
STOP: End all electrical power to the
vehicle.
LIGHTS ON: Turn the headlights on. The
engine stop switch must be in the RUN
position.
START: Start the engine. After releasing the
key, the switch returns to the LIGHTS ON position. See page 65 for
starting procedures.
Engine Stop Switch
Move the stop switch left or right to the OFF
position to stop the engine. Move the switch 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.
Override Switch
See page 33.
4X4 Switch
See page 33.
Mode/Reverse
Override
Switch
Main Key
Switch
4X4
Switch
Headlight Switch
Engine Stop
Switch
STOP
LIGHTS ON
START
OFF OFFRUN
33
FEATURES AND CONTROLS
Switches
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system. To gain
additional wheel speed while backing, release the throttle and depress
the override switch.
Pressing the override switch 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 switch.
The reverse override switch also acts as a MODE button when held
down for approximately one half second. The transmission cannot be in
reverse when using the override switch as a MODE button.
4X4 Switch
Use the 4X4 switch to engage 4WDC, 4X4 or 2X4. See page 42.
The vehicle automatically engages 4X4 when operating in reverse if the
switch is set to either 4X4 position.
Fuel Tank
Always refuel with the engine stopped, and
outdoors or in a well ventilated area.
Refuel on a level surface.
Remove the fuel tank cap and add fuel.
Use either leaded or unleaded gasoline
with a minimum pump octane number of
87=(R+ M/2) octane. Do not use fuel with
ethanol content greater than 10 percent,
such as E-85 fuel.
The fuel tank is designed to allow for the normal expansion of fuel. Do
not overfill. Do not fill the tank neck.
Extreme Use Battery
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to
operation in extreme cold or due to extended use of multiple electrical
accessories, please see your POLARIS dealer. Ask your dealer to
provide any installation procedures that may differ for an extreme use
battery.
Fuel Tank
Cap
34
FEATURES AND CONTROLS
Mirrors (if equipped)
Use the mirrors to assist in traffic maneuvers. Always check and adjust
the mirrors before driving.
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.
35
FEATURES AND CONTROLS
Brakes
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.
Foot Brake
The all-wheel foot brake is located
on the right footrest. The foot brake
operates both front and rear brakes.
Press the brake pedal down with
your foot to apply the all-wheel
brakes.
If the rear wheels begin to skid or
slide while using the foot brake,
reduce brake pressure.
Hand Brake Lever
The hand brake operates both front
and rear brakes. Squeeze the brake
lever toward the handlebar to apply
the all-wheel brakes.
If the rear wheels begin to skid or
slide while using the brake, reduce
lever pressure.
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.
Foot
Brake
36
FEATURES AND CONTROLS
Brakes
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.
Operating the vehicle while the parking brake is engaged could result in an
accident and serious injury or death. Always release the parking brake lock
before operating.
Steering Lock (if equipped)
Lock the steering to prevent unauthorized use or theft of the vehicle.
1. Turn the handlebars to the full left position.
Tip: The handlebars may also be locked in the full right position.
2. Insert the steering lock key and turn it clockwise.
3. Remove the key.
Tip: 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.
37
FEATURES AND CONTROLS
Electronic Power Steering (EPS)
Electronic power steering engages when the ignition key is turned to the
ON position. EPS remains engaged whether the vehicle is moving or
idle. See page 45 for EPS Warning Indicator information.
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
Stop the vehicle, release the
throttle and move the shift lever
to the desired gear. See your
dealer if you experience any
shifting problems.
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. The transmission is locked when it’s in PARK.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at
less than 11 km/h for extended periods and when operating uphill at a
slow speed.
Gear
Selector
38
FEATURES AND CONTROLS
Front Compartment
Front Rack (SPORTSMAN XP 1000)
Release the front rack
latches and remove the rack
to gain access to the front
compartment. To reinstall
the rack, hold the rack as
shown in the illustration.
Position the front edge in the
tabs, then push the rack
downward and secure the
latches.
Brake Fluid
Reservoir
Fuse Box/Relay
Recovery
Bottle Cap
Battery
Radiator
Cap
Recovery
Bottle
Cap
Radiator
Cap
Battery
Fuse Box/Relay
Foot Brake Fluid Reservoir
SPORTSMAN
SCRAMBLER
Latches
39
FEATURES AND CONTROLS
Front Compartment
Front Storage Box (Touring)
Open the front storage box to access the
under-compartment area.
1. Release the front box cover latches
and lift the cover.
2. Release the plunger latches that
secure the box to the frame.
3. Close the cover and lift the
unlatched edge of the box to
disengage the plungers. Pivot the
box forward.
4. To remove the box completely,
disengage the plungers and slide the
box rearward and upward.
5. Always secure the plunger latches
and the cover latches before
operating the vehicle.
Front Rack/Compartment
(SCRAMBLER)
Release the front rack latches and
remove the rack to gain access to
the front compartment.
To reinstall the rack, hold the rack
as shown in the illustration.
Position the front edge in the tabs,
then push the rack downward and
secure the latches.
Cover Latches
Plunger Latches
Latches
40
FEATURES AND CONTROLS
Hitches
See the specification section beginning on page 148 for hitch weight
capacities.
Do not tow a vehicle or a trailer with this vehicle unless all instructions have
been followed. See pages 80-82.
Whenever the vehicle is towing, always stay clear of the area between the
vehicle and the towed object.
Rear Hitch (Zugmachine)
Use the rear hitch for towing a trailer. See pages 80-82 for procedures.
Rear Hitch Certification Label (Zugmachine)
The hitch certification label is located near the hitch on models
equipped with a factory-installed rear hitch.
Rear Hitch Specifications
Material S355J2+N
Fasteners Metal pin with security cotter pin
Weld Length and Positions 4 mm fillet, all around
Maximum Vertical Load 75 kg applied on coupling point
Maximum Towable Mass 750 kg
Approval # E9-55R-01 6121
41
FEATURES AND CONTROLS
Hitches
Hitch Removal/Installation
1. To remove the hitch, remove the cotter pin and hitch pin. Remove
the hitch, then reinstall the hitch pin and secure the cotter pin.
2. To install the hitch, remove the cotter pin from the hitch pin and
remove the hitch pin.
3. Install the hitch to the receiver.
4. Reinstall the hitch pin (from the left side of the hitch) through the
bore of both the receiver and the hitch.
5. Reinstall the cotter pin. Make sure the hitch assembly is secure at
that the cotter pin is properly engaged over the hitch pin.
7-Way Trailer Connector (Zugmachine)
The 7-way trailer connector
installed on your vehicle meets the
requirements of European standard
ISO 1724.
This connector uses all 7 pins on
newer model trailers. An older
model trailer may not be
compatible with this connector.
Improper electrical wiring changes
can result in damage to both
vehicle and trailer components. When in doubt about your trailer
connection, please contact a qualified towbar specialist for assistance.
Cotter Pin
Hitch Pin
Step 4
Step 5
7-Way Trailer Connector
42
FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system
is controlled by the AWD
momentary switch.
Engage AWD before getting
into conditions where front
wheel drive may be needed.
If the rear wheels are
spinning, release the throttle
before switching to AWD.
NOTICE: Switching to AWD or 4WDC AWD (if equipped) while the rear wheels
are spinning may cause severe drive shaft and gearcase damage.
Always switch to AWD or 4WDC AWD (if equipped) while the rear
wheels have traction or are at rest.
AWD Mode
Move the momentary switch to the far right
to engage AWD. AWD will engage when
engine speed slows to below 3100 RPM.
The gauge will display “AWD”.
There is no limit to the length of time the
vehicle may remain in AWD. The vehicle
automatically engages AWD when operating in reverse if the switch is
set to the AWD position.
Once enabled, AWD remains enabled until the switch is turned off. If
the switch is turned off while the demand drive unit is moving, it will
not disengage until the rear wheels regain traction.
When in AWD, the demand drive unit will automatically engage any
time the rear wheels lose traction. When the rear wheels regain traction,
the demand drive unit will automatically disengage.
2X4 Mode
Move the momentary switch to the far left
to operate in two-wheel drive. AWD will
disengage when engine speed slows to
below 3100 RPM. The gauge will display
“2X4”.
AWD
Switch
RPM
FE
88
:
88
RPM
FE
88
:
88
43
FEATURES AND CONTROLS
All Wheel Drive System
4WDC AWD Mode (if equipped)
Move the momentary switch to the right,
past the AWD setting, to engage 4WDC (if
equipped). When the switch is on 4WDC,
the ADC system allows engine braking to
all four wheels when the vehicle descends a
hill or incline. Always move the 4X4
switch to 4WDC before ascending or descending a hill.
Four-Wheel Descent Control (4WDC) System
The 4WDC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to
4WDC before ascending or descending a hill.
Engaging Four-Wheel Descent Control
The 4WDC system will automatically engage when all four of the
following conditions occur:
• The 4X4 switch must be in the 4WDC position
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Four-Wheel Descent Control
The 4WDC system will automatically disengage if at least one of the
following conditions occur:
• The 4X4 switch is moved out of the 4WDC position
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
• The vehicle is on flat ground, or not actively descending a hill
RPM
FE
88
:
88
44
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage ATV components. Wash the ATV
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).
Rider
Information
Center
Speedometer
Indicator Lamps
45
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.
EPS Warning This indicator illuminates when the key is turned to
the ON position and goes off when the engine is
started. If the light remains on after starting the
engine, the EPS system is inoperative. See your
authorized POLARIS dealer for service.
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.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the ATV if this warning appears.
Serious engine damage could result. See your dealer.
46
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 ATV 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 48.
Trip 1
km
mi
RPM
EF
88
:
88
1
2
6
5
7
3
4
47
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. Four-Wheel Descent Control Display - This icon displays when
4WDC is active. See page 45.
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 49 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 49 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either 4WDC or 4X4).
48
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
Time 12-Hour Clock 24-Hour Clock
49
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 ATV.
Trip Meter Mode
The trip meter records the distance traveled by the ATV 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.
50
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.
51
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.See pages 58-61 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)
52
FEATURES AND CONTROLS
Instrument Cluster
Digital Gauge (if equipped)
The instrument cluster displays critical vehicle information to the user.
Reference the following page for display functions and descriptions.
NOTE: Some features are not applicable to all models.The use of a high pres-
sure washer may damage the instrument cluster. Wash the vehicle by
hand or with a garden hose using mild soap. Certain products, includ-
ing insect repellents and chemicals, will damage the instrument cluster
lens. 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.
53
FEATURES AND CONTROLS
Instrument Cluster
Premium Gauge
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. Display Area 2 - This area displays odometer, trip meter, trip meter
2, voltage, engine temperature, engine hour meter, programmable
service hour interval, ground speed, or engine RPM.
3. Display Area 1 - This area displays engine RPM, ground speed, or
coolant temperature.
4. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.
5. Service Indicator - A flashing wrench symbol alerts the operator
that the preset service interval has been reached. Your POLARIS
dealer can provide scheduled maintenance. See page 60 for more
information.
6. Clock - The clock displays time in a 12-hour or 24-hour format. See
page 56 for more information.
7. AWD Indicator - Segments of the indicator illuminate based on
drive mode engaged.
54
FEATURES AND CONTROLS
Instrument Cluster
Indicator Lamps
Lamp Indicates Condition
1 Check Engine This indicator appears if an EFI related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. Your autho-
rized POLARIS dealer can assist.
2EPS Warning
(if equipped)
This indicator illuminates when a fault has occurred
in the EPS system. Your authorized POLARIS
dealer can assist. EPS operation is possible with
key on/engine off for up to 5 minutes.
3 Engine Hot This lamp illuminates to indicate an overheated
engine. If the indicator flashes, a severe overheating
condition exists.
4 Neutral This lamp when the transmission is in neutral and
the ignition key is on the ON position.
5 Helmet/Seat Belt This lamp flashes for several seconds when the key
is turned to the ON position. The lamp is a reminder
to wear helmet and seat belt before operating.
6 High Beam This lamp illuminates when the headlamp switch is
set to high beam.
7 Chassis Fault Not applicable.
8 Performance
Limited
Not applicable.
55
FEATURES AND CONTROLS
Instrument Cluster
Display Area 1
Pressing the MODE button will change the information displayed in
Area 1.
Display Area 1 options:
•Speed
•RPM
• Engine Temperature
• Ambiant Temperature (optional)
56
FEATURES AND CONTROLS
Instrument Cluster
Display Area 2
Toggle the UP/DOWN buttons to change the information displayed in
Area 2.
Display Area 2 options:
•Odometer
•Trip 1
•Trip 2
• Voltage
•Trip Timer
• Engine Tempurature
• Ambiant Temperature (optional)
•RPM
•Engine Hours
•Service Hours
•Speed
57
FEATURES AND CONTROLS
Instrument Cluster
Options Menu
Press and hold the MODE button to enter the Options Menu.
Options Menu Notes
Diagnostic Codes Only displays if fault codes are present or stored
Units - Distance Select MPH or KPH
Units - Temp
Select between
°F and °C
Clock Select between 12H or 24H, and set time
Backlight Color Select between Blue or Red
Backlight Level Set backlight brightness level
Service Hours View/Set Service hours
Exit Menu Exit
58
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.
Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor Voltage Too High 51 3
Voltage Too Low 51 4
Engine Temperature Sensor Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0
Intake Air Temperature Sensor Voltage Too High 105 3
Voltage Too Low 105 4
Manifold Absolute Pressure Sensor Voltage Too High 102 3
Voltage Too Low 102 4
Signal Out of Range 102 2
Crankshaft Position Sensor Circuit Fault 636 8
Plausibility Fault 636 2
Vehicle Speed Signal Speed Too High 84 8
Plausibility Fault 84 2
Gear Sensor Signal Voltage Too Low 523 4
Voltage too high 523 3
Signal fault 523 2
Injector 1 (MAG) (SDI Part Load) Driver Circuit Open/Grounded 651 5
Driver Circuit Short to B+ 651 3
Driver Circuit Grounded 651 4
Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded 652 5
Driver Circuit Short to B+ 652 3
Driver Circuit Grounded 652 4
59
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3
Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3
Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5
Driver Circuit Short to B+ 1347 3
Driver Circuit Grounded 1347 4
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5
Driver Circuit Short to B+ 1071 3
Driver Circuit Grounded 1071 4
Idle Air Control Driver Circuit Open/Grounded 634 5
Driver Circuit Short to B+ 634 3
Driver Circuit Grounded 634 4
Position Out of Range 634 7
Starter Enable Circuit Driver Circuit Open/Grounded 1321 5
Driver Circuit Short to B+ 1321 3
Driver Circuit Grounded 1321 4
Chassis Relay Driver Circuit Open/Grounded 520208 5
Driver Circuit Short to B+ 520208 3
Driver Circuit Grounded 520208 4
All Wheel Drive Control Driver Circuit Open/Grounded 520207 5
Driver Circuit Short to B+ 520207 3
Driver Circuit Grounded 520207 4
System Power Voltage Too High 168 3
Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3
Voltage Too Low 520194 4
Signal Out of Range 520194 2
Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Open/Grounded 520203 5
Driver Circuit Short to B+ 520203 3
Driver Circuit Grounded 520203 4
Idle Speed Speed Too High 520211 3
Speed Too Low 520211 4
60
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
EPS Models Only
Vehicle Speed Sensor Data Valid But Above Normal
Operational Range - Most
Severe Level
84 0
Data Erratic, Intermittent Or
Incorrect
84 2
Abnormal Rate Of Change 84 10
Received Network Data In Error 84 19
System Power Data Valid But Above Normal
Operational Range - Most
Severe Level
168 0
Voltage Above Normal, Or
Shorted To High Source
168 3
Voltage Below Normal, Or
Shorted To Low Source
168 4
Engine Speed Data Valid But Above Normal
Operational Range - Most
Severe Level
190 0
Data Erratic, Intermittent Or
Incorrect
190 2
Received Network Data In Error 190 19
ECU Memory Bad Intelligent Device Or
Component
628 12
Out Of Calibration 628 13
Calibration Out Of Calibration 630 13
Steering Over Current Shut Down Current Above Normal Or
Grounded Circuit
520221 6
Steering Excessive Current Error Current Above Normal Or
Grounded Circuit
520222 6
Steering Torque Partial Failure Condition Exists 520223 31
Steering Torque Full Failure Condition Exists 520224 31
61
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
EPS Models Only
EPAS Inverter Temperature Data Valid But Above Normal
Operational Range - Most
Severe Level
520225 0
Data Valid But Above Normal
Operating Range - Moderately
Severe Level
520225 16
EPAS Communications Receive
Data Error
Data Erratic, Intermittent Or
Incorrect
520226 2
Condition Exists 520226 31
Position Encoder Error Root Cause Not Known 520228 11
Bad Intelligent Device Or
Component
520228 12
Condition Exists 520228 31
EPAS Software Error Bad Intelligent Device Or
Component
520229 12
Condition Exists 520229 31
EPAS Power Save Condition Condition Exists 520231 31
EPS SEPIC Voltage Error Voltage Above Normal, Or
Shorted To High Source
524086 3
Voltage Below Normal, Or
Shorted To Low Source
524086 4
62
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.
63
OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 33. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 101. 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 64.
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.
64
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 latch (if
equipped)
Ensure latch is secure 115
Hand brake/lever travel Ensure proper operation 113
Foot brake Ensure proper operation 113
Brake fluid Ensure proper levels 111
Front suspension Inspect, lubricate if necessary 100
Rear suspension Inspect, lubricate if necessary 100
Steering Ensure free operation -
Tires Inspect condition and pressure 117
Wheels/fasteners Inspect, ensure fastener tightness 117
118
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 33
101
Coolant level Ensure proper level 109
110
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation 34
Indicator lights/switches Ensure proper operation 27
Engine stop switch Ensure proper operation 28, 32
Air filter, pre-filter Inspect, clean 119
Headlights Check operation 28, 32
Brake light/tail lamp Check operation 123
Riding gear Wear approved helmet, goggles, and
protective clothing
17
Mirrors (if equipped) Adjust for best side/rear vision -
Winch (if equipped) Inspect cable and switch. 83-94
65
OPERATION
Starting the Engine
1. Position the vehicle on a level surface.
2. Place the transmission in PARK.
Tip: The starter interlock will prevent the engine from starting if the transmission
is in gear and the brake is not engaged.
3. Sit on the vehicle. Move the engine stop switch to RUN.
4. Do not press the throttle while starting the engine.
5. Turn the ignition key to the START 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.
See your POLARIS dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.
66
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 17.
2. Perform the pre-ride inspection. See page 64.
3. Place the transmission in PARK.
4. Mount the vehicle from the left side.
5. Sit upright with both feet on the footrests. Keep both hands on the
handlebars.
6. Start the engine and allow it to warm up.
7. Apply the brakes.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the brakes.
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.
67
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.
4. Never turn quickly when carrying a passenger or cargo.
Always follow the procedures outlined in this
manual for turning. Never turn sharply at
excessive speeds, which can lead to vehicle
overturn.
68
OPERATION
Driving with a Passenger
1. Never carry a passenger on a 1-up vehicle. Never carry more than
one passenger on a 2-up vehicle.
2. Do not carry a passenger on a 2-up vehicle until you have at least
two hours of driving experience with the vehicle.
3. Never allow anyone under 12 years of age to ride as a passenger on
a 2-up vehicle. Make sure any passenger is tall enough to
comfortably and safely reach the grab handles and footrests. Allow
a passenger to ride only in the approved passenger seat.
4. Make sure the passenger is wearing appropriate riding gear,
including an approved helmet with a rigid chin guard. See page 17.
5. Perform the pre-ride
inspection. See page 64.
6. Always make sure the
passenger seat is installed
and securely latched before
operating with a passenger.
7. Lock the parking brake.
8. 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.
9. Do not 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.
69
OPERATION
Driving with a Passenger
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.
12. Do not cross a hillside with a passenger on board. See page 76.
13. A passenger should always be seated behind the operator with both
hands on the passenger grab handles at all times. The passenger
should never hold on to the operator. Never secure a passenger to
the vehicle or to the operator with a belt, rope or similar device.
14. Make sure the passenger understands the importance of “active rid-
ing.” 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.
70
OPERATION
Driving on Slippery Surfaces
Whenever driving on slippery or loose surfaces such as wet trails,
gravel, snow or ice, follow these precautions:
1. Slow down when entering slippery areas.
2. 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.
3. Be alert. Watch the trail. Avoid quick, sharp turns
4. 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.
Always follow the procedures outlined in this
manual for operating on slippery or loose
surfaces. Use extra caution. Always avoid
skidding or sliding.
Sideways
Skid
Turn in direction
of skid
71
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: If the vehicle stops while fully submerged, major engine damage can
result if the machine is not thoroughly inspected. Take the vehicle to
your dealer before starting the engine.
5. Wet brakes may have reduced stopping ability. Dry the brake pads
by driving slowly and applying the brakes lightly several times until
braking action is normal.
6. If your vehicle becomes fully immersed, and it’s impossible to take
it to a dealer before starting it, follow the steps described on page
127. Have the vehicle serviced by your dealer promptly.
Always follow the procedures outlined in this
manual for driving through water. Never drive
through deep or fast-flowing water.
Maximum
Depth
72
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 attempt to operate over large obstacles, such as rocks or
fallen trees.
4. Always have a passenger dismount before operating over an
obstacle that could cause a fall from the vehicle or vehicle rollover.
Always follow the procedures outlined in this manual for operating over
obstacles.
73
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. 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.
Always follow the procedures outlined in this manual for driving in reverse.
74
OPERATION
Driving Uphill
Whenever traveling uphill, follow these precautions:
1. Always move the 4X4 switch to 4WDC before ascending or
descending a hill. See page 42.
2. Drive straight uphill.
3. Avoid steep hills. Maximum incline is:
• 15° (2-Up Models)
• 25° (1-Up Models)
4. Avoid hills with slippery or loose surfaces.
5. Keep both feet on the footrests.
6. Shift body weight uphill. A passenger should also shift body weight
uphill.
7. Proceed at a steady rate of speed to avoid stalling.
8. Be alert. Be prepared to take emergency action. This may include
dismounting quickly.
9. Never open the throttle suddenly or make sudden gear changes.
10. Never go over the top of a hill at high speed.
1-Up Models
25° Maximum
2-Up Models
15° Maximum
75
OPERATION
Driving Uphill
If all forward speed is lost:
1. Keep your weight uphill. A passenger should also lean uphill.
2. If the vehicle begins rolling downhill, never apply engine power.
Never apply the brakes aggressively while rolling backwards.
3. Apply the brakes gradually. When fully stopped, lock the hydraulic
parking brake.
4. Dismount on the uphill side, or on the left side if the vehicle is
pointed straight uphill. Have a passenger dismount first, then the
operator may dismount.
5. Use the K-turn to turn around. See page 78.
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.
76
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. Shift body weight uphill.
3. Keep your feet on the footrests.
4. Avoid hills with slippery or loose surfaces.
5. Avoid crossing the sides of steep hills.
6. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.
7. If the vehicle begins to slide or tip, quickly turn the front wheel
downhill, if possible, or dismount on the uphill side immediately!
Always follow the procedures outlined in this
manual for crossing the side of a hill.
Never attempt to turn the vehicle around on
any hill until you've mastered (on level
ground) the turning technique outlined in this
manual.
77
OPERATION
Driving Downhill
When driving downhill, follow
these precautions:
1. Always move the 4X4 switch
to 4WDC before ascending or
descending a hill. See page
42.
2. Avoid steep hills. Maximum
incline is:
• 15° (2-Up Models)
• 25° (1-Up Models)
3. Avoid hills with slippery or
loose surfaces.
4. Never drive downhill at high speed. Slow down.
5. Drive straight downhill. Avoid driving downhill at an angle, which
can cause the vehicle to pitch 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.
Always follow the procedures outlined in this
manual for driving downhill and for braking on
hills.
78
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
1. Stop the vehicle. Keep your weight uphill.
2. Always move the 4X4 switch to 4WDC before ascending or
descending a hill. See page 42.
3. Lock the hydraulic parking brake.
4. Leave the transmission in forward gear. Turn the engine off.
5. 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.
6. Stay uphill of the vehicle and turn the handlebars full left.
7. Squeeze the brake lever to release the parking brake.
8. Slowly release the brake lever and allow the vehicle to roll around
to your right until it's pointing across the hill or slightly downward.
2.4 m
79
OPERATION
Turning Around on a Hill (K-Turn)
9. Lock the hydraulic parking brake.
10. Remount from the uphill side. Keep your weight uphill. A passenger
should not remount until the vehicle returns to firm, level ground.
11. Apply the foot brake.
12. With the transmission still in forward, start the engine.
13. Squeeze and release the brake lever to release the parking brake.
14. Release the foot brake and drive slowly downhill. Control speed
with either the hand or foot brake until the vehicle is on level
ground.
Always follow the procedures outlined in this
manual for driving on hills. See page 74.
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 25°.
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.
80
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 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.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO OR TOWING. Use extreme caution when applying
brakes. Avoid situations that require backing downhill.
• WEIGHT DISTRIBUTION on models with front and rear racks should be 1/3
on the front rack and 2/3 on the rear rack. Carrying loads on only one rack
increases the possibility of vehicle overturn.
• CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads
high on the racks raises the center of gravity of the vehicle and creates a less
stable operating condition.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the
vehicle.
• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.
• HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.
• USE EXTREME CAUTION when operating with loads that extend over the
rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.
• Towing is approved OFF-ROAD ONLY unless your vehicle is approved for on-
road operation.
• 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.
81
OPERATION
Hauling Cargo
1. Never exceed the weight
capacities specified for your
vehicle on warning labels and in
the specifications section of this
manual.
2. On models with front and rear
racks, cargo weight should be
evenly distributed (1/3 on the
front rack and 2/3 on the rear
rack) and mounted as low as
possible.
3. When operating over rough or
hilly terrain, reduce speed and cargo weight to maintain stable
driving conditions.
4. All Models except SCRAMBLER:
NEVER exceed 80 km/h when rear cargo loads are above 34 kg
and/or front cargo loads are above 17 kg.
5. Touring Models only:
NEVER exceed 80 km/h while carrying a passenger.
NEVER exceed 16 km/h when rear cargo loads are above 91 kg
and/or front cargo loads are above 45 kg.
6. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
1/3
2/3
82
OPERATION
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY unless your vehicle is approved
for on-road operation. 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 rack cargo weight by the amount of
tongue weight. The combination of rear rack cargo weight and tongue
weight must not exceed the rear rack capacity.
• The total load (operator, passenger, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.
• For Zugmachine, unbraked trailer towing capacity is 180 kg based on
EU Directive 76/432/EC. Braked trailer towing capacity is 805 kg.
• For all other models, unbraked trailer towing capacity is 750 kg based
on EU Directive 76/432/EC.
NOTICE: Using an improper hitch or exceeding the maximum tongue weight
capacity can result in serious damage to the vehicle and will void
your vehicle 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.
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. Always block the rear
wheels on the downhill
side.
83
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 92.
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
84
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 90 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.
85
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.
86
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
87
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 92.
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
88
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.
89
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 92. 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.
90
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.
91
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
92
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.
93
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.
94
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.
95
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 Arrester
Your POLARIS vehicle has a spark arrester that was designed for on-
road and off-road operation. It is required that this spark arrester 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. The emissions label is located on the right front frame of the
vehicle.
Electromagnetic Interference
This vehicle complies with the EMC requirements of European
directive 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 EN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was
controlled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
96
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.
Record maintenance and service in the Maintenance Log beginning on
page 160.
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.
97
MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
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.
Perform all services at whichever maintenance interval is reached first.
Symbol Description
► Perform these operations more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
See Pre-Ride Checklist on
page 64.
Front suspension - -
Rear suspension - -
Tires - -
Brake fluid level - -
Brake lever travel - -
Brake system - -
Wheels/fasteners - -
Frame fasteners - -
Engine oil level - -
Winch - - See pages 83-94.
► Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed. See page 119.
Coolant - Daily - Check level
► Power steering unit
(if equipped)
- Daily - Inspect daily; clean often
Headlamp/taillight - Daily - Check operation
► Air filter, main
element
- Weekly - Inspect; replace as needed.
See page 119.
98
MAINTENANCE
Periodic Maintenance Chart
► Perform these procedures more often for vehicles subjected to severe use.
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
► Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test
Fuel system 20 H Monthly - Inspect; cycle key to
pressurize fuel pump; check
lines and fittings for leaks and
abrasion
► Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change
(see page 62)
► Demand drive fluid
(extreme use)
25 H 1 M 250 (400) Change fluid every 25 hours
if 4WDC is subjected to
extreme use. See page 105.
► 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 Throttle Cable/
Throttle Release
Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper
sealing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; 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
99
MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
► 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
D Fuel system 100 H 12 M 1000 (1600) Cycle key to pressurize fuel
pump; check for leaks at fill
cap, fuel lines/rail and fuel
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 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
Spark arrester 300 H 36 M 3000 (4800) Clean out
► Coolant - 60 M - Replace coolant
D Valve clearance 1000 H - 10000
(16000)
Inspect; adjust
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
100
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 96. Items not listed in
the chart should be lubricated at the General Lubrication interval.
The a-arms and lower 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)
--- 12 ft. lbs.
(16 Nm)
Page 101.
Transmission
Oil
AGL Gearcase
Lubricant &
Transmission
Fluid
37 oz.
(1100 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 104.
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 105.
Rear
Gearcase Oil
ATV Angle Drive
Fluid (or GL5 80-
90 weight gear
lube)
7.1 oz.
(210 ml)
10-14 ft. lbs.
(14-19 Nm)
10-14 ft. lbs.
(14-19 Nm)
Page 106.
Brake Fluid DOT 4 Brake
Fluid
--- --- --- Page 111.
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
101
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 147 for the part numbers of POLARIS
products.
See the table on page 100 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.
Oil Level
Check the oil level when the
engine is cold. Never check the
oil with the engine running.
Access the oil dipstick and fill
tube from the left side of the
vehicle.
1. Position the vehicle on a
level surface. Place the
transmission in PARK.
2. 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
102
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 100 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 96. Always change
the oil filter whenever changing oil.
1. Position the vehicle on a level surface. Place the transmission in
PARK.
2. Start the engine. Allow it to warm up at idle for two to three
minutes.
3. Stop the engine.
4. SCRAMBLER: On the bottom of the vehicle, a guard plate covers
the oil filter access hole. Remove the three bolts securing the guard
plate and remove the guard plate.
5. Clean the area around the drain plug.
6. Place a drain pan under the crankcase.
7. 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.
8. 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.
9. Reinstall the drain plug. Torque to specification.
Drain Plug
Front
Filter Access
Top View
Guard Plate
(SCRAMBLER)
103
MAINTENANCE
Engine Oil
Oil and Filter Change
10. Place shop towels beneath the oil filter.
Using an oil filter wrench (available
from your POLARIS dealer), turn the
filter counter-clockwise to remove it.
11. Using a clean dry cloth, clean the filter
sealing surface on the crankcase.
12. Lubricate the o-ring on the new filter
with a film of fresh engine oil. Check to
make sure the o-ring is in good
condition.
13. Install the new filter and rotate it
clockwise by hand until the filter gasket
contacts the sealing surface, then turn it
an additional 3/4 turn.
14. Remove the dipstick. Add the proper amount of the recommended
oil. Do not overfill.
15. Reinstall the dipstick.
16. SCRAMBLER: Reinstall the guard plate over the filter access hole.
17. Place the transmission in PARK.
18. Start the engine. Allow it to idle for one to two minutes.
19. Stop the engine.
20. Check for leaks.
21. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
22. Dispose of used filter and oil properly.
Oil Filter
104
MAINTENANCE
Transmission Oil
See the table on page 100 for fluid recommendations, capacities and
plug torques. Always check and change the transmission oil at the
intervals outlined in the Periodic Maintenance Chart beginning on page
96. See page 147 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 116).
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.
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.
Drain Plug
Fill Plug
Fill
Level
105
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 100 for fluid recommendations, capacities and
plug torques. Always check and change the demand drive fluid at the
intervals outlined in the Periodic Maintenance Chart beginning on page
96. See page 147 for the part numbers of POLARIS products.
4WDC Models: Change the front gearcase fluid every 25 hours if the
4WDC unit is exposed to extreme use. Extreme use includes any of the
following:
• operation in 4WDC mode for prolonged periods
• constant 4WDC operation on hilly or mountainous terrain
• 4WDC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase is makes excessive noise during 4WDC operation,
change the demand drive fluid. If the noise continues, please see your
POLARIS dealer for service.
Use the recommended fluid. Use of other fluids may result in improper
operation of components. Maintain the fluid level at the bottom of the
fill hole threads. 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.
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.
Drain Plug
Fill
Plug
Fill
Level
106
MAINTENANCE
Rear Gearcase Oil
See the table on page 100 for fluid recommendations, capacities and
plug torques. Always check and change the rear gearcase oil at the
intervals outlined in the Periodic Maintenance Chart beginning on page
96. See page 147 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
107
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.
108
MAINTENANCE
Power Steering Unit
If your model is equipped with
power steering, frequently
clean the areas around and on
the power steering unit to
allow proper cooling. Clean
these areas thoroughly.
Cooling System
The engine coolant level is controlled by the recovery system. Recovery
system components are the recovery bottle, the radiator filler neck, the
radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the engine, past the pressure cap, and into
the recovery bottle. As engine coolant temperature decreases the
contracting (cooled) coolant is drawn back up from the bottle, past the
pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix.
This antifreeze is already premixed and ready to use. Do not dilute with
water. See page 147 for the part numbers of POLARIS products.
Clean
often
109
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 rack.
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 rack.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
Radiator
Cap
Recovery
Bottle Cap
Radiator
Cap
SPORTSMAN
SCRAMBLER
110
MAINTENANCE
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every five (5) years
and fresh Antifreeze 50/50 Premix added.
Any time the cooling system has been drained for maintenance or repair,
replace the coolant with fresh Antifreeze 50/50 Premix.
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 rack.
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 rack.
Recovery
Bottle Cap
Radiator
Cap
Recovery
Bottle Cap
Radiator
Cap
SPORTSMAN
SCRAMBLER
111
MAINTENANCE
Brake Fluid
Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.
The brakes should feel firm when they’re applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for
service.
Operating the vehicle with a spongy brake can result in loss of braking, which
could cause an accident. Never operate the vehicle with spongy-feeling brakes.
If the fluid level is low add DOT 4 brake fluid only. See page 147 for the
part numbers of POLARIS products.
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.
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.
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 accident or severe injury. After opening a bottle of brake
fluid, always discard any unused portion.
112
MAINTENANCE
Brake Fluid
Hand Brake
The master cylinder is located on
the left handlebar. Maintain the
fluid level 6 mm below the top
edge of the master cylinder. Do
not overfill.
1. Position the vehicle on a
level surface. Make sure the
handlebars are straight.
2. View the fluid level through
the indicator window (eye)
on the top of the master
cylinder.
Tip: The eye will appear dark when
the fluid level is full. When fluid
is low, the eye will be clear.
3. If the fluid level is low,
remove the cover screws and
add fluid to the fill line. Do
not overfill.
4. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).
Foot Brake
The foot brake fluid reservoir is located under the front rack.
Master
Cylinder
Indicator
Window
Full
Low
Foot Brake Fluid Reservoir
SPORTSMAN SCRAMBLER
113
MAINTENANCE
Brake Inspections
The front and rear brakes are hydraulic disc brakes, activated by
applying the foot brake. The handlebar brake is also hydraulic. Both
brake systems are self-adjusting.
Perform the following checks to keep the brake systems 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 112.
2. Check the brake systems regularly for
fluid leaks.
3. Check the brakes for excessive travel or
spongy feel.
4. Check the friction pads for wear, damage
and looseness. Replace the pads when the
friction material is worn to 0.762 mm.
5. Check the security and surface condition
of the disc. Clean any grease using a
recommended brake cleaner or alcohol. Do not use spray lubricants
or other petroleum-based products. If you discover any damage
(cracks, excessive corrosion, warping) see your dealer for service
before operating.
0.762 mm
114
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 3-6 mm more than the front measurement on each side of
the vehicle to obtain the recommended 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.
String
Stand
2
1
115
MAINTENANCE
Steering Assembly
The steering assembly 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.
Seat Removal
1. Grasp one side of the seat
near the rear edge.
2. Pull upward abruptly to
disengage the under-seat
fasteners.
3. Remove the seat.
Passenger Seat Removal (Touring)
To remove the passenger
seat, pull the top of the
seatback slightly rearward
to relieve tension (1) while
pulling the seat release latch
upward (2). When the latch
releases, roll the seat
assembly forward (3) and
lift the seat away from the
vehicle.
Always make sure the
passenger seat is properly
installed and securely
latched before operating
with a passenger.
Passenger Seat
Release Latch
1
2
3
116
MAINTENANCE
Side Panel/Footwell Removal
Remove the seat before removing a side panel. Remove the screws and
rivets securing the side panel or footwell (see illustration).
Plastic Rivet
Hex Head Screw
Plastic Rivet
Plastic Rivet
Torx Head
Screw
SPORTSMAN model shown
117
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 148 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. Loosen the wheel nuts slightly.
Do not service axle nuts that have a cotter pin installed. See your POLARIS
dealer.
4. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.
5. Remove the wheel nuts.
6. Remove the wheel.
1/8" (3 mm)
118
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. 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).
3. Install the wheel nuts and finger-tighten them.
4. Lower the vehicle to the ground.
5. 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 maintenance service.
Wheel Type Nut Torque
All 102 Nm
119
MAINTENANCE
Air Filter
1. Remove the seat.
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.
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 rack.
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 rack.
Main
Filter
Pre-Filter
Strap
SPORTSMAN
SCRAMBLER
Fuse
Box/Relay
120
MAINTENANCE
Lights
Headlight Beam Adjustment
The headlight beam can be adjusted slightly upward or downward.
1. Position the vehicle on a level surface. The headlight should be
approximately 7.6 m from a wall.
2. Place the transmission in PARK.
3. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
NOTE: Include rider weight on the seat when measuring.
4. Start the engine.Turn the headlight switch to high beam.
5. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be 5 cm below the mark on the wall.
6. Tighten or loosen the three (3)
headlight screws to adjust the
beam upward or downward or to
the left or right.
7.6 m
5 cm
X
X
Screws
SCRAMBLER shown
121
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/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
122
MAINTENANCE
Lights
Front Turn Signal Replacement
If a front turn signal light (also rear
signal light on SCRAMBLER) becomes
inoperable, the lamps cannot be
replaced. Replace the entire signal lamp
assembly.
Rear Turn Signal Lamp Replacement (SPORTSMAN)
1. Place the transmission in PARK.
2. Rotate the turn signal socket
counter-clockwise to remove it.
3. Remove the lamp.
4. Apply dielectric grease to the
socket.
5. Install the new lamp. Test the
lamp for proper operation.
6. Reinstall all components in reverse order.
Rear Stop/Turn Signal Lamp Replacement
(SCRAMBLER)
If a light becomes inoperable, the lamps cannot be repaired. Replace the
entire signal lamp assembly.
123
MAINTENANCE
Lights
Taillight/Brakelight Lamp Replacement (SPORTSMAN)
1. Place the transmission in
PARK.
2. Rotate the taillight socket
counter-clockwise to
remove it.
3. Remove the lamp.
4. Apply dielectric grease to
the socket.
5. Install the new lamp. Test
the lamp for proper
operation.
6. Reinstall all components in reverse order.
Taillight/Brakelight Lamp Replacement (SCRAMBLER)
The taillight assembly is not serviceable. If the light fails to operate
properly, replace the entire taillight assembly.
Taillight/Brakelight/Turn Signal Lamp Replacement
(SCRAMBLER ZUGMACHINE)
The taillight assembly is not serviceable. If the light fails to operate
properly, replace the entire taillight assembly.
124
MAINTENANCE
Front/Rear Shock Compression (SCRAMBLER)
The compression damping clicker knob is located on the top of the front
shock reservoir and on the bottom of the rear shock reservoir. When the
knob is turned clockwise until it stops, the damping is in the fully closed
position.
1. Turn the clicker clockwise to increase compression damping.
2. Turn the clicker counter-clockwise to decrease compression
damping.
FOX Shocks
Setting Compression Damping
Softest 20 clicks from closed
Factory 10 clicks from closed
Firmest 2 clicks from closed
Decrease
Increase
Front
+-
Rear
D
e
c
r
e
a
s
e
I
n
c
r
e
a
s
e
+
-
125
MAINTENANCE
Front and Rear Springs (SPORTSMAN)
The front and rear shock absorber
springs are adjusted by rotating the
adjuster either clockwise or
counter-clockwise to increase or
decrease spring tension. Accessory
springs are available through your
POLARIS dealer.
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 (if equipped).
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
14-17 Nm, then torque the rear
two bolts. A gap of up to 3 mm
will remain at the rear of the
clamp blocks.
Adjuster
Handlebar
Bolts
126
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 148 for the
recommended spark plug type and gap for your vehicle.
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
plugs for correct color. See page 126.
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Rotate the spark plug counter-clockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to
specification.
Normal 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.
Plug Condition Torque Specification
New Spark Plug 18-20 ft. lbs. (24-27 Nm)
Previously Installed Spark Plug 18-20 ft. lbs. (24-27 Nm)
127
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. If
equipped, remove the air box drain
plug to drain water. Make sure the
E-ring is on the drain plug and
reinstall the drain plug.
NOTICE: Serious damage could occur if
the air box drain plug is not
reinstalled and tightened
properly
.
3. Remove the spark plugs.
4. Turn the engine over several times
using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying
procedure.
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 132 for drying out the PVT.
Drain Plug
128
MAINTENANCE
Spark Arrester
Failure to heed the following warnings while servicing the spark arrester could
result in serious injury or death. Never run the engine in an enclosed area.
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
arrester 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.
Arrestor Cleaning (SPORTSMAN)
1. Remove the arrester 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. Repeat steps 4 to 6 until no more
particles are expelled.
9. Stop the engine. Allow the arrester to cool.
10. Reinstall the arrester clean-out plug and remove the exhaust outlet
cover or plug.
Clean-Out Plug
129
MAINTENANCE
Spark Arrester
Arrestor Cleaning (SCRAMBLER)
If your model is equipped with dual exhaust, periodically perform the
following procedure for both arresters to remove accumulated carbon.
1. Remove the retaining nut. Remove the arrester from the end of the
muffler.
2. Use a non-synthetic brush to clean the arrester screen. A synthetic
brush may melt if components are warm. If necessary, blow debris
from the screen with compressed air.
3. Inspect the screen for wear and damage. Replace a worn or
damaged screen.
4. Reinstall the arrester. Torque the nut to 10-12 Nm.
Arrester
Retaining
Nut
Screen
Muffler
130
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.
131
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.).
132
MAINTENANCE
PVT System
When To Use Low Range and High Range
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
133
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 rack.
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.
134
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 135
before installing the battery.
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to
operation in extreme cold or due to extended use of multiple electrical
accessories, please see your POLARIS dealer. Ask your dealer to
provide any installation procedures that may differ for an extreme use
battery.
1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
8. Install the front rack.
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to
make up for normal self-discharge. Battery Tender can be left connected
during the storage period, and will automatically charge the battery if
the voltage drops below a pre-determined point. See page 147 for the
part numbers of POLARIS products.
135
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. The battery should be disconnected from a load or charger for at
least two hours before checking voltage. Check the battery voltage
with a voltmeter or multimeter. A fully charged battery will register
12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger
manufacturer's instructions for recharging. When using a constant
current charger, use the guidelines on the next page for recharging.
136
MAINTENANCE
Battery
Battery Charging (Sealed Battery)
Always verify battery condition before and 1-2 hours after the end of
charging.
State of
Charge
Voltage Action
Charge Time
(Using constant current
charger @ standard amps
specified on top of battery)
100% 12.8-13.0 volts None, check at 3
mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight
charge, if no
charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,
verify state of charge
0%-25% 11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
137
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.
138
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
139
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 then clean the vehicle as recommended.
See page 137.
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.
Oil and Filter
Change the oil and filter. See page 102.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
119.
2. Clean the air box.
140
MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the following fluid levels. Change fluids as recommended in the
Periodic Maintenance Chart beginning on page 96.
• Demand drive unit (front gearcase)
• Rear gearcase
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength)
Fog the Engine
1. Treat the fuel system with POLARIS Carbon Clean, following the
instructions on the container. Run the engine for several minutes so
the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To
access the plug holes, use a section of clear 1/4" hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap and
reinstall the caps onto the plugs.
5. Turn the engine over several times using electric start. Oil will be
forced in and around the piston rings and ring lands, coating the
cylinder with a protective film of fresh oil.
6. If POLARIS fuel system additive is not used, the fuel tank, fuel
lines, and injectors should be completely drained of gasoline.
141
MAINTENANCE
Cleaning and Storage
Storage Tips
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended
in the Periodic Maintenance Chart beginning on page 96.
Battery Maintenance
Remove the battery and recharge it as outlined on page 135. Store the
battery in a cool, dry place.
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.
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
use on this vehicle.
142
MAINTENANCE
Transporting the Vehicle
1. Stop the engine.
2. Place the transmission in PARK.
3. Secure the fuel cap, oil cap and seat.
4. 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, racks or handlebars.
5. Remove the key to prevent loss during transporting.
SPORTSMAN model shown
143
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
78).
Driving at low RPM or
ground speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
See page 132.
Insufficient warm-up at
low ambient
temperatures
Warm the engine at least 5 minutes. With the transmission
in neutral, advance the throttle to about 1/8 throttle in
short bursts, 5 to 7 times. The belt will become more
flexible and prevent belt burning.
Slow/easy clutch
engagement
Use the throttle quickly and effectively.
Towing/pushing at low
RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
WARNING! Excessive throttle may cause loss of
control and vehicle 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 132. 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 63.
144
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 plugs 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 plugs
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
145
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 plugs 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 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
Electronic throttle control 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
operating and/or stopping
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
146
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 plugs Inspect, clean and/or replace spark plug
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
Electronic throttle control 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.
147
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
2880514 Antifreeze 50/50 Premix (qt./.95 l)
2880513 Antifreeze 50/50 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
148
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN XP 1000 Zugmachine
Maximum Weight Load Capacity 261 kg
Dry Weight 398 kg +/- 5 %, based on configuration
Fuel Capacity 20 L
Engine Oil Capacity 1.9 L
Coolant Capacity 1.9 L
Rear Gearcase Oil Capacity 210 ml
Demand Drive Fluid Capacity 275 ml
Transmission Oil Capacity 1100 ml
Front Rack/Storage Box Capacity 55 kg
Rear Rack Capacity 110 kg
Hitch Tongue Weight 80 kg (Rear rack capacity and tongue weight
not to exceed 80 kg)
Hitch Towing Rating 805 kg on level ground
Unbraked Trailer Towing Capacity* 180 kg
Braked Trailer Towing Capacity* 805 kg
Overall Length 228 cm
Overall Width 123 cm
Overall Height 141 cm (with mirrors installed)
Wheelbase 134.6 cm
Ground Clearance 29.5 cm
Minimum Turning Radius 213 cm unloaded
Fuel System Bosch Multi-Port Sequential Electronic Fuel
Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Engine EHO952LE
Displacement 952 cc
Engine Power 65.6 kW
Bore x Stroke 90.5 x 74
Alternator Output 475w @1200 RPM/Peak 575w
Compression Ratio 11:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM 1200 +/- 50
Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm
Throttle Body/Size Mikuni Dual Bore/42 mm
Spark Plug Type / Gap AUTOLITE 5682 / 0.76 mm
Throttle System Electronic Throttle Control (ETC)
Lubrication System Wet Sump
Seat Single Seat, length 650 mm
Steering System Akerman Principle, with handlebar controls
149
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN XP 1000 Zugmachine
Transmission Power System Shaft drive on all wheels
Driving System Type Automatic PVT (POLARIS Variable Transmission)
Front Suspension Dual a-arm with 23 cm travel
Rear Suspension Progressive rate with 26 cm travel
Transmission and Gears High/Low/Neutral/Reverse/Parking
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires Type/Pressure Front Off Road Style, Deep Tread Design,
size 26x8-14 AT / 45 kPa/0.5 bar
Tires Type/Pressure Rear Off Road Style, Deep Tread Design,
size 26x10-14 AT / 45 kPa/0.5 bar
Brakes, Front/Rear Single-Control handlebar hydraulic disc on all
wheels
Brakes, Auxiliary Foot-Activated Hydraulic Disc on all wheels
Brake, Parking Hydraulic lock on all wheels, Mechanical Lock in
Park
Hitch Rear mounting for attachment of coupling devices
Winch Front permanent installed winch with 1125 kg
capacity
Headlight 2 Dual beam on bumper (55/60 watt)
1 Single beam on headlight pod (50 watt)
2 Hi/Lo beam on bumper (55/60 watt)
Taillights 7 watts
Brake Light 27 watts
Work Light Halogen, 50 watt
Fog Light Rear, incandescent, 5 watt
License Plate Lamp 1,25 watt LED
Instrument Cluster Digital/Analog
12V DC Outlet Yes
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-70
PN 5633136
Orange
PN 7044279
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
1800-3700
(6000-12000)
24-68
PN 5632418
Orange
PN 7044279
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
150
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN 1000 / SPORTSMAN XP 1000
Maximum Weight Load Capacity 261 kg
Dry Weight 378 kg +/- 5 %, based on configuration (1000)
398 kg +/- 5 %, based on configuration (XP 1000)
Fuel Capacity 20 L
Engine Oil Capacity 1.9 L
Coolant Capacity 1.9 L
Rear Gearcase Oil Capacity 210 ml
Demand Drive Fluid Capacity 275 ml
Transmission Oil Capacity 1100 ml
Front Rack/Storage Box Capacity 55 kg
Rear Rack Capacity 110 kg
Hitch Tongue Weight 75 kg (Rear rack capacity and tongue weight not
to exceed 75 kg)
Hitch Towing Rating 750 kg on level ground
Unbraked Trailer Towing
Capacity*
868 kg
Overall Length 211 cm
Overall Width 121 cm
Overall Height 129 cm
Wheelbase 134.6 cm
Ground Clearance 29.5 cm
Minimum Turning Radius 213 cm unloaded
Fuel System Bosch Multi-Port Sequential Electronic Fuel
Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Engine EHO952LE
Displacement 952 cc
Engine Power 65.6 kW
Bore x Stroke 90.5 x 74
Alternator Output 475w @1200 RPM/Peak 575w
Compression Ratio 11:1
Starting System Electric
Ignition System Electronic Fuel Injection
Idle RPM 1200 +/- 50
Ignition Timing 6 +/- 5 BTDC @ 1200 RPM, Engine warm
Throttle Body/Size Mikuni Dual Bore/42 mm
Spark Plug Type / Gap AUTOLITE 5682 / 0.76 mm
Throttle System Electronic Throttle Control (ETC)
Lubrication System Wet Sump
151
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN 1000 / SPORTSMAN XP 1000
Seat Single Seat, length 650 mm
Steering System Akerman Principle, with handlebar controls
Transmission Power System Shaft drive on all wheels
Driving System Type Automatic PVT (POLARIS Variable
Transmission)
Front Suspension Dual a-arm with 23 cm travel
Rear Suspension Progressive rate with 26 cm travel
Transmission and Gears High/Low/Neutral/Reverse/Parking
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires Type/Pressure Front Off Road Style, Deep Tread Design,
size 26x8-14 AT / 45 kPa
Tires Type/Pressure Rear Off Road Style, Deep Tread Design,
size 26x10-14 AT / 45 kPa
Brakes, Front/Rear Single-Control handlebar hydraulic disc on all
wheels
Brakes, Auxiliary Foot-Activated Hydraulic Disc on all wheels
Brake, Parking Hydraulic lock on all wheels, Mechanical Lock in
Park
Hitch Rear mounting for attachment of coupling
devices
Winch (XP 1000) Front permanent installed winch with 1125 kg
capacity
Headlight 2 Dual beam on bumper (55/60 watt)
1 Single beam on headlight pod (50 watt)
2 Hi/Lo beam on bumper (55/60 watt)
Taillights 7 watts
Brake Light 27 watts
Instrument Cluster Digital/Analog
12V DC Outlet Yes
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-70
PN 5633136
Orange
PN 7044279
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
1800-3700
(6000-12000)
24-68
PN 5632418
Orange
PN 7044279
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
152
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SPORTSMAN XP Touring 1000
Maximum Weight Capacity 261 kg (includes operator, passenger, cargo,
accessories)
Dry Weight 416 kg
Fuel Capacity 20 L
Engine Oil Capacity 1.9 L
Coolant Capacity 1.9 L
Demand Drive Fluid Capacity 275 ml
Transmission Fluid Capacity 1100 ml
Rear Gearcase Fluid Capacity 210 ml
Front Rack/Storage Box Capacity 55 kg
Rear Rack Capacity 110 kg
Hitch Tongue Weight 75 kg (Rear rack capacity and tongue weight not
to exceed 75 kg)
Hitch Towing Rating 750 kg on level ground
Unbraked Trailer Towing
Capacity*
750 kg
Overall Length 219.7 cm
Overall Width 121 cm
Overall Height 148 cm
Wheelbase 145 cm
Ground Clearance 29.5 cm
Minimum Turning Radius 244 cm unloaded
Fuel System Bosch Multi-Port Sequential Electronic Fuel
Injection
Fuel Delivery Electronic Fuel Pump (in tank)
Engine EHO952LE
Displacement 952 cc
Bore x Stroke 90.5 x 74
Alternator Output 475w @ 1200 RPM/Peak 630w
Compression Ratio 11.0:1
Starting System Electric
Ignition System Electronic Fuel Injection
Ignition Timing 6° +/- 5° BTDC @ 1200 RPM
Idle RPM 1200 +/- 50
Throttle Body/Size Mikuni Dual Bore/42 mm
Spark Plug / Gap AUTOLITE 5682 / 0.76 mm
Throttle System Electronic Throttle Control (ETC)
153
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SPORTSMAN XP Touring 1000
Lubrication System Pressurized Wet Sump
Transmission Type Automatic PVT (POLARIS Variable
Transmission) In-Line H-L-N-R-P
Front Suspension Dual a-arm, 22.9 cm travel
Rear Suspension Dual a-arm with Rolled IRS, 25.4 cm travel
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tire Size/Pressure, Front 26x9-14 / 45 kPa
Tire Size/Pressure, Rear 26x10-14 / 45 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 Dual beam on bumper (55/60 watt)
1 Single beam on headlight pod (50 watt)
2 Hi/Lo beam on bumper (55/60 watt)
Taillight 12v/7 watts
Brake Light 12v/27 watts
Instrumentation Digital/Analog
12V DC Outlet Yes
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-70
PN 5633136
Orange
PN 7044279
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
1800-3700
(6000-12000)
24-60
PN 5632216
Purple
PN 7043805
Black/White
Lettering
PN 7044086
58-66F 45°BA
PN 3235630
154
SPECIFICATIONS
* Based on EU Directive 76/432/EC
SCRAMBLER 1000 / SCRAMBLER XP 1000
Maximum Weight Capacity 131 kg (includes operator, cargo and accessories)
Dry Weight 371 kg +/- 5 %, based on configuration (1000)
375 kg +/- 5 %, based on configuration (XP 1000)
Fuel Capacity 20 L
Engine Oil Capacity 1.9 L
Coolant Capacity 1.9 L
Rear Gearcase Oil Capacity 210 ml
Demand Drive Fluid Capacity 275 ml
Transmission Oil Capacity 1100 ml
Front Rack Capacity 11 kg
Rear Rack Capacity 23 kg
Receiver Hitch Tongue Capacity 75 kg
Hitch Towing Rating 750 kg
Unbraked Trailer Towing
Capacity*
868 kg
Overall Length 209.5 cm
Overall Width 122 cm
Overall Height 125.7 cm)
Wheelbase 134.6 cm
Ground Clearance 27 cm
Minimum Turning Radius 213 cm unloaded
Displacement 952 cc
Bore x Stroke 90.5 x 74
Alternator Output 475w @1200 RPM/Peak 630w
Compression Ratio 11:1
Starting System Electric
Ignition System Electronic Fuel Injection
Ignition Timing 6° +/- 5° BTDC @ 1200 RPM
Idle RPM 1200 +/- 50
Throttle Body/Size Mikuni Dual Bore/42 mm
Spark Plug Type / Gap AUTOLITE 5682 / 0.76 mm
Throttle System Electronic Throttle Control (ETC)
Lubrication System Wet Sump
Driving System Type Automatic PVT (POLARIS Variable
Transmission)
155
SPECIFICATIONS
Clutching
*EBS models require no helix/spring adjustment
SCRAMBLER 1000 / SCRAMBLER XP 1000
Front Suspension Dual a-arm with 23 cm travel (1000)
Dual a-arm with FOX Podium X Shocks (XP 1000)
Rear Suspension Progressive rate with 26 cm travel(1000)
Dual a-arm with FOX Podium X Shocks (XP 1000)
Transmission H/L/N/R/P
Gear Reduction, Low 5.034:1
Gear Reduction, Reverse 4.508:1
Gear Reduction, High 2.367:1
Drive Ratio, Front 3.818:1
Drive Ratio, Rear 3.7:1
Tires/Pressure, Front 26x8-14 / 35 kPa
Tires/Pressure, Rear 26x10-14 / 35 kPa
Hand Brake Single-Control Hydraulic Disc, All Wheel
Foot Brake Foot-Activated Hydraulic Disc, All Wheel
Brake, Parking Hydraulic Lock, All Wheel
Mechanical Lock in PARK
Headlight 2 Hi/Lo beam on bumper (55/60 watt)
Taillight/Brake Light LED
Instrument Cluster Digital/Analog
12V DC Outlet Yes
Altitude Shift
Weight
Drive
Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
24-70
PN 5633136
Red/Black
Stripe
PN 7043500
Black/White
Lettering
PN 7044086
58-66F
Parallel BA
PN 3235590
1800-3700
(6000-12000)
24-68
PN 5632418
Red/Black
Stripe
PN 7043500
Black/White
Lettering
PN 7044086
58-66F
Parallel BA
PN 3235590
156
WARRANTY
Limited Warranty
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a
TWO YEAR LIMITED WARRANTY on all components of your POLARIS vehicle
against defects in material or workmanship. POLARIS further warrants that the spark
arrester in this product will meet the efficiency requirements of USFS standard 5100-1C
for at least 1000 hours when subjected to normal use and when maintenance and
installation are in accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts
and begins on the date of purchase by the original retail purchaser. This warranty is
transferable to another owner during the warranty period through a POLARIS dealer,
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 racing, competition or purposes other than
for which it was designed.
This warranty excludes damages or failures resulting from improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external stress,
heat, cold or contamination; operator error or abuse; improper component alignment,
tension, adjustment or altitude compensation; snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket or unapproved components, accessories, or attachments; unauthorized
repairs; or repairs made after the warranty period expires or by an unauthorized repair
center.
157
WARRANTY
Warranty Coverage And Exclusions:
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 CONSEQUENTIAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL
SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS
ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE TWO YEAR 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
•Filters •Sealants
• Lubricants • Coolants
• Bushings • Bearings
158
WARRANTY
How To Obtain Warranty Service
If your vehicle requires warranty service, you must take it to a POLARIS Servicing
Dealer. When requesting warranty service you must present your copy of the Warranty
Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND
FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use
your original selling dealer; however, you may use any POLARIS Servicing Dealer to
perform warranty service.
In the Country where your product was purchased:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. 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.
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.
159
WARRANTY
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.
160
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
161
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
162
INDEX
Numerics
4WDC System. . . . . . . . . . . . . . . . . 43
4X4 Switch . . . . . . . . . . . . . . 27, 31-33
A
Access, Front Compartment . . . . . . 38
Accessories . . . . . . . . . . . . . . . . . . 141
Age Restrictions. . . . . . . . . . . . . . . . . 8
Air Filter . . . . . . . . . . . . . . . . . . . . 119
All Wheel Drive System . . . . . . . 42-43
AWD Momentary Switch . . . . . . . . 42
B
Battery . . . . . . . . . . . . . . . . . . . 133-136
Charging . . . . . . . . . . . . . . . . . . 135
Charging (Sealed Battery) . . . . 136
Extreme Use Battery. . . . . . . . . . 33
Installation . . . . . . . . . . . . . . . . 134
Removal . . . . . . . . . . . . . . . . . . 133
Storage . . . . . . . . . . . . . . . . . . . 134
Belt Life. . . . . . . . . . . . . . . . . . . . . . 37
Boots . . . . . . . . . . . . . . . . . . . . . . . . 18
Box, Front (Touring) . . . . . . . . . . . . 39
Brake Fluid . . . . . . . . . . . . . . . 111-112
Brake Inspections. . . . . . . . . . . . . . 113
Brake Lever . . . . . . . . . . . . . . . . . . . 35
Brake, Foot . . . . . . . . . . . . . . . 35, 112
Brake, Hand Lever. . . . . . . . . . . . . 112
Brake, Parking . . . . . . . . . . . . . . . . . 36
Brakes . . . . . . . . . . . . . . . . . . . . . 35-36
Break-In Period . . . . . . . . . . . . . . 62-63
C
Cargo . . . . . . . . . . . . . . . . . . . . . . 80-82
Check Engine Indicator . . . . . . . . . . 51
Cleaning and Storage. . . . . . . . 137-141
Clothing . . . . . . . . . . . . . . . . . . . . . . 18
Clutching
Scrambler 1000. . . . . . . . . . . . . 155
Scrambler XP 1000. . . . . . . . . . 155
Sportsman 1000 . . . . . . . . . . . . 151
Sportsman XP 1000 . . . . . . . . . 151
Sportsman XP Touring 1000 . . 153
Zugmachine . . . . . . . . . . . . . . . 149
Cold Weather Operation . . . . . . . . . 65
Compartment, Front. . . . . . . . . . . 38-39
Coolant Bottle . . . . . . . . . . . . . . . . 109
Coolant, Radiator. . . . . . . . . . . . . . 110
Cooling System . . . . . . . . . . . . 108-110
D
Demand Drive Fluid . . . . . . . . . . . . 105
Diagnostic Codes. . . . . . . . . . . . . 58-61
Disengaging Descent Control . . . . . . 43
Display Units, Standard/Metric. . . . . 48
Drive Belt Wear/Burn . . . . . . . . . . . 143
Drivetrain Break-In . . . . . . . . . . . . . . 63
Driving Downhill. . . . . . . . . . . . . . . . 77
Driving in Reverse. . . . . . . . . . . . . . . 73
Driving on a Sidehill . . . . . . . . . . . . . 76
Driving on Slippery Surfaces . . . . . . 70
Driving Over Obstacles. . . . . . . . . . . 72
Driving Procedures . . . . . . . . . . . . . . 66
Driving Through Water . . . . . . . . . . . 71
Driving Uphill . . . . . . . . . . . . . . . 74-75
Driving with a Passenger. . . . . . . 68-69
E
Electromagnetic Interference. . . . . . . 95
Electronic Power Steering. . . . . . . . . 37
Engaging Descent Control. . . . . . . . . 43
Engine Break-In. . . . . . . . . . . . . . . . . 63
Engine Fogging . . . . . . . . . . . . . . . . 140
Engine Oil . . . . . . . . . . . . . . . . 101-103
Engine Stop Switch . . . . . . . . . . . 28, 32
EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Equipment Modifications . . . . . . . . . . 9
Error Codes, Engine . . . . . . . . . . . . . 51
European Vibration and Noise . . . . . 95
Exhaust Emission Control System . . 95
Extreme Use Battery . . . . . . . . . . . . . 33
Eye Protection . . . . . . . . . . . . . . . . . . 18
163
INDEX
F
Fluid
Brake . . . . . . . . . . . . . . . . . 111-112
Coolant. . . . . . . . . . . . . . . . 108-110
Demand Drive . . . . . . . . . . . . . . 105
Engine Oil . . . . . . . . . . . . . 101-103
Rear Gearcase . . . . . . . . . . 106-107
Transmission Oil . . . . . . . . . . . . 104
Fluid Change
Demand Drive . . . . . . . . . . . . . . 105
Engine Oil . . . . . . . . . . . . . 102-103
Rear Gearcase . . . . . . . . . . . . . . 107
Transmission . . . . . . . . . . . . . . . 104
Fluid Level
Demand Drive . . . . . . . . . . . . . . 105
Engine Oil . . . . . . . . . . . . . . . . . 101
Rear Gearcase . . . . . . . . . . . . . . 106
Transmission . . . . . . . . . . . . . . . 104
Foot Brake. . . . . . . . . . . . . . . . . . . . . 35
Footwell Removal. . . . . . . . . . . . . . 116
Front Box (Touring) . . . . . . . . . . . . . 39
Front Compartment. . . . . . . . . . . 38-39
Front Gearcase (Demand Drive). . . 105
Fuel Safety . . . . . . . . . . . . . . . . . . . . 16
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 33
Fuse Replacement. . . . . . . . . . . . . . 119
G
Gasoline Handling . . . . . . . . . . . . . . 16
Gauge, Code Definitions. . . . . . . 58-61
Gauge, Digital/Analog . . . . . . . . 44-51
Gear Selector. . . . . . . . . . . . . . . . . . . 37
Gearcase Oil, Rear . . . . . . . . . 106-107
Gloves. . . . . . . . . . . . . . . . . . . . . . . . 18
H
Hand Brake . . . . . . . . . . . . . . . . . . . 112
Handlebar Adjustment . . . . . . . . . . 125
Hauling Cargo. . . . . . . . . . . . . . . 80-82
Hazard Warning Switch . . . . . . . 28, 31
Headlight Beam Adjustment. . . . . . 120
Headlight Lamp . . . . . . . . . . . . . . . 121
Headlight Switch. . . . . . . . . . . . . 28, 32
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 17
High Beam Switch, Momentary . 28-29
High Range Use . . . . . . . . . . . . . . . 132
Hitch Certification Label . . . . . . . . . 40
Hitches . . . . . . . . . . . . . . . . . . . . 40-41
Horn Switch . . . . . . . . . . . . . . . . 28, 31
I
Immersion. . . . . . . . . . . . . . . . . . . . 127
Indicator Lamps . . . . . . . . . . . . . 45, 54
Instrument Cluster . . . . . . 44-51, 58-61
K
Key Switch . . . . . . . . . . . . . . 27, 30, 32
K-Turn . . . . . . . . . . . . . . . . . . . . 78-79
L
Light Switch . . . . . . . . . . . . . . . . . . . 29
Light Switch, High/Low Beam. . . . . 30
Lights . . . . . . . . . . . . . . . . . . . 120-123
Headlight Beam Adjustment . . . 120
Headlight Lamp . . . . . . . . . . . . . 121
Momentary High Beam Switch . . 28
Position Light Lamp . . . . . . . . . 121
Lamp Replacement . . . . . 122, 123
Turn Signal Replacement. . . . . . 122
Low Range Use. . . . . . . . . . . . . . . . 132
Lubrication Guide. . . . . . . . . . . . . . 100
M
Maintenance Chart . . . . . . . . . . . 96-99
Metric Display . . . . . . . . . . . . . . . . . 48
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 34
Mode Switch. . . . . . . . . . . . . . . . . . . 29
Modifications . . . . . . . . . . . . . . . . . . . 9
N
Noise Emission Control System. . . . 95
164
INDEX
O
Oil
Engine. . . . . . . . . . . . . . . . . 101-103
Rear Gearcase . . . . . . . . . . . 106-107
Transmission. . . . . . . . . . . . . . . 104
Oil and Filter Change. . . . . . . . 102-103
Oil Change
Rear Gearcase . . . . . . . . . . . . . . 107
Transmission. . . . . . . . . . . . . . . 104
Oil Level
Engine. . . . . . . . . . . . . . . . . . . . 101
Rear Gearcase . . . . . . . . . . . . . . 106
Transmission. . . . . . . . . . . . . . . 104
Oil Recommendations . . . . . . . . . . 101
Override Switch. . . . . . . . . . . . . 29, 33
P
Parking Brake . . . . . . . . . . . . . . . . . 36
Parking on an Incline. . . . . . . . . . . . 82
Periodic Maintenance Chart . . . . 96-99
Polaris Product List . . . . . . . . . . . . 147
Polishing the Vehicle. . . . . . . . . . . 138
Position Light Lamp . . . . . . . . . . . 121
Power Steering. . . . . . . . . . . . . . . . . 37
Power Steering Unit (Cleaning). . . 108
Pre-Ride Checklist. . . . . . . . . . . . . . 64
PVT Break-In. . . . . . . . . . . . . . . . . . 63
PVT Drying . . . . . . . . . . . . . . . . . . 132
PVT System. . . . . . . . . . . . . . . 130-132
R
Rack, Front (SCRAMBLER). . . . . . 39
Registration, Warranty. . . . . . . . . . 156
Reverse Operation . . . . . . . . . . . . . . 73
Reverse Override Switch. . . . . . 29, 33
Rider Information Center. . . . . . . 46-51
Rider Safety. . . . . . . . . . . . . . . . . 10-16
Riding Gear . . . . . . . . . . . . . . . . . 17-18
S
Safety Labels . . . . . . . . . . . . . . . . 19-26
Safety Training . . . . . . . . . . . . . . . . . . 8
Safety, Winch Maintenance. . . . . . . . 94
Seat Removal. . . . . . . . . . . . . . . . . . 115
Seat Removal, Passenger. . . . . . . . . 115
Severe Use. . . . . . . . . . . . . . . . . . . . . 96
Shock Compression. . . . . . . . . . . . . 124
Shock Loading the Winch . . . . . . 92-93
Side Panel Removal. . . . . . . . . . . . . 116
Sidehilling . . . . . . . . . . . . . . . . . . . . . 76
Signal Words . . . . . . . . . . . . . . . . . . . . 5
Spark Arrester . . . . . . . . . . . . . 128-129
Spark Arrester Requirements. . . . . . . 95
Spark Plug Inspection . . . . . . . . . . . 126
Spark Plug Recommendations. . . . . 126
Spark Plugs . . . . . . . . . . . . . . . . . . . 126
Speedometer . . . . . . . . . . . . . . . . . . . 44
Spring Adjustment, Shock. . . . . . . . 125
Starting the Engine . . . . . . . . . . . . . . 65
Steering Assembly. . . . . . . . . . . . . . 115
Steering Lock. . . . . . . . . . . . . . . . . . . 36
Stop Switch . . . . . . . . . . . . . . . . . . . . 28
Storage. . . . . . . . . . . . . . . . . . . 137-141
Storage Box, Front (Touring) . . . . . . 39
Storage Tips. . . . . . . . . . . . . . . 139-141
Switches. . . . . . . . . . . . . . 27-28, 30-33
4X4 Switch . . . . . . . . . . . . 27, 31-33
AWD Momentary Switch. . . . . . . 42
Engine Stop Switch. . . . . . 28, 30, 32
Fog Light Switch . . . . . . . . . . 27, 29
Hazard Warning . . . . . . . . . . . . . . 31
Hazard Warning Switch . . . . . . . . 28
Headlight Switch . . . . . . . 28, 30, 32
Horn . . . . . . . . . . . . . . . . . . . . . . . 31
Horn Switch . . . . . . . . . . . . . . . . . 28
Light Switch . . . . . . . . . . . . . . . . . 30
Main Key Switch . . . . . . . 27, 30, 32
Mode Switch. . . . . . . . . . . . . . . . . 33
Mode/Reverse Override Switch . . 29
Momentary High Beam . . . . . 28-29
Stop Switch. . . . . . . . . . . . . . . . . . 28
Turn Signal . . . . . . . . . . . . . . . . . . 31
Turn Signal Switch . . . . . . . . . . . . 28
Winch Switch . . . . . . . . . . . . . . . . 29
Work Light . . . . . . . . . . . . . . . . . . 31
Work Light Switch . . . . . . . . . . . . 27
165
INDEX
T
Taillight. . . . . . . . . . . . . . . . . . . . . . 123
Throttle Lever . . . . . . . . . . . . . . . . . . 34
Tires . . . . . . . . . . . . . . . . . . . . 117-118
Tread Depth . . . . . . . . . . . . . . . . 117
Wheel Hub Tightening. . . . . . . . 117
Wheel Installation . . . . . . . . . . . 118
Wheel Nut Torque . . . . . . . . . . . 118
Wheel Removal . . . . . . . . . . . . . 117
Toe Alignment . . . . . . . . . . . . . . . . 114
Towing Loads. . . . . . . . . . . . . . . . . . 82
Training. . . . . . . . . . . . . . . . . . . . . . . . 8
Transmission Gear Selector . . . . . . . 37
Transmission Oil. . . . . . . . . . . . . . . 104
Transporting the Vehicle . . . . . . . . 142
Turn Signal Lamp Replacement . . . 122
Turn Signal Replacement, Front. . . 122
Turn Signal Switch . . . . . . . . . . . 28, 31
Turning Around on a Hill . . . . . . 78-79
Turning the Vehicle . . . . . . . . . . . . . 67
V
Vehicle Identification Numbers . . . . . 7
Vehicle Immersion . . . . . . . . . . . . . 127
W
Warning Symbols . . . . . . . . . . . . . . . . 5
Washing the Vehicle. . . . . . . . 137-138
Wheel Hub Tightening . . . . . . . . . . 117
Wheel Installation. . . . . . . . . . . . . . 118
Wheel Nut Torque . . . . . . . . . . . . . 118
Wheel Removal . . . . . . . . . . . . . . . 117
Winch Cable Care. . . . . . . . . . . . . . . 91
Winch Maintenance/Service Safety . 94
Winch Operation. . . . . . . . . . . . . 86-90
Winch Safety Precautions. . . . . . 83-85
Winch Shock Loading . . . . . . . . 92-93
For your nearest Polaris dealer,
visit www.polaris.com
Polaris Sales Europe Sarl
Route de l’Etraz
Business Center A5
1180 Rolle, Switzerland
Part No. 9927460 Rev 02
PMS 419
