Polaris Scrambler XP 1000 S Owner's Manual
The Polaris Scrambler XP 1000 S is a powerful and versatile off-road vehicle designed for adventure. It features a 999cc ProStar engine for thrilling performance and a durable steel frame for rugged durability. With its 4x4 system, you can conquer any terrain with ease. Whether you're trail riding, exploring new territory, or tackling challenging obstacles, the Scrambler XP 1000 S is ready to deliver an unforgettable experience.
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SCRAMBLER XP® 1000 S
Owner's Manual For Maintenance and Safety
Read this manual carefully. It contains important safety information.
This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
!
WARNING
Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.
Failure to follow the safety precautions could result in serious injury or death.
!
WARNING
Operating, servicing, and maintaining a passenger vehicle or off-road vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize exposure, avoid breathing exhaust, do not idle the engine ex cep or wash your hands frequently when servicing your vehicle. t as necessary, service your vehicle in a well-ventilated area and wear gloves For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR code with your smartphone.
2020 Owner’s Manual
Scrambler XP® 1000 S
POLARIS®, ACE™, OUTLAW®, SPORTSMAN®, and SCRAMBLER® are trademarks of POLARIS Industries Inc.
Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.
Printed in U.S.A.
9930001
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational products. We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever produced.
• Snowmobiles • SPORTSMAN® All-terrain vehicles • RZR® sport vehicles • GEM® vehicles • Low emission vehicles (LEVs) •
RANGER
® utility vehicles • INDIAN® motorcycles • POLARIS POWER® generators • POLARIS® PRO XD™ work vehicles • SLINGSHOT® three wheel motorcycles • POLARIS DEFENSE® combat vehicles • Timbersled® Snow Bikes For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during, and after, the warranty period.
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Introduction . . . . . . . . . . . . . . . . . . . . 7
Safety . . . . . . . . . . . . . . . . . . . . . . 11
Features and Controls . . . . . . . . . . . . . . 27
Operation . . . . . . . . . . . . . . . . . . . . 57
Winch Guide. . . . . . . . . . . . . . . . . . . 75
Emission Control Systems . . . . . . . . . . . . . 85
Maintenance . . . . . . . . . . . . . . . . . . 87
Specifications . . . . . . . . . . . . . . . . . . 127
POLARIS Products . . . . . . . . . . . . . . . . 131
Troubleshooting . . . . . . . . . . . . . . . . . 133
Warranty . . . . . . . . . . . . . . . . . . . . 137
Maintenance Log . . . . . . . . . . . . . . . . 145
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INTRODUCTION IMPORTANT WARNING ABOUT THIS MANUAL
WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV.
• Never operate an ATV without proper instruction. Take a certified ATV safety training course (www.atvsafety.org).
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course (www.atvsafety.org).
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SAFETY SYMBOLS AND SIGNAL WORDS
The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.
DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury.
WARNING WARNING indicates a hazardous situation which, if not avoided, COULD result in death or serious injury.
CAUTION CAUTION indicates a hazardous situation which, if not avoided, COULD result in minor to moderate injury.
NOTICE
NOTICE provides key information by clarifying instructions.
IMPORTANT IMPORTANT provides key reminders during disassembly, assembly, and inspection of components.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.
The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors, including: • Instrument and calibration uncertainty • Variations in the machine such as wear of components • Variation of machine operators such as experience or physique • Ability of the worker to reproduce typical work during measurements • Environmental factors such as ambient noise or temperature
VEHICLE IDENTIFICATION NUMBERS
The vehicle identification number (VIN) can be found stamped on the right rear frame tube q .
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Vehicle Model Number Frame VIN q Engine Serial Number w Key Number 9
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SAFETY SAFETY TRAINING
ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course.
If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV regular basis.
RiderCourse
sm that is available to you and your eligible family members. This training is included in the purchase price of your ATV. You were also provided with printed materials that explain safe operating procedures. You should review this information on a If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV
RiderCourse
sm for a fee. Call ATV Enrollment Express at (800) 887- 2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the United States, please contact your dealer or local law enforcement agencies for information about safety training.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your vehicle manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.
SAFE RIDING GEAR
Always wear helmet, eye protection, gloves, long- sleeve shirt, long pants, over-the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury. q Helmet w Eye Protection e Long Sleeves r Gloves t Long Pants y Over-the-Ankle Boots 11
HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.
Parents should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.
Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
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SAFETY WARNINGS
WARNING Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain.
All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle.
All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid driver’s license.
The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel (if equipped) or handlebars.
USING ALCOHOL OR DRUGS
WARNING Never consume alcohol or drugs before or while operating this vehicle.
Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.
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FAILURE TO INSPECT BEFORE OPERATING
WARNING Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.
Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.
Always follow the inspection and maintenance procedures and schedules described in this owner’s manual.
HANDLING GASOLINE
Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated area.
• Never carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
EXPOSURE TO EXHAUST
CAUTION Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.
PROTECTIVE APPAREL
Riding in this vehicle without wearing an approved helmet and protective eye wear increases the risk of a serious injuries in the event of an accident.
Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.
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OPERATING ON PAVEMENT
This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.
OPERATING ON PUBLIC ROADS
Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).
OPERATING AT EXCESSIVE SPEEDS
Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience.
PHYSICAL CONTROL OF THE VEHICLE
Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.
If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.
Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
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TURNING IMPROPERLY
CAUTION Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.
JUMPS AND STUNTS
Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.
IMPROPER HILL CLIMBING
Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See the New Operator Driving Procedures section for details.
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual. See the New Operator Driving Procedures section for details.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See the New Operator Driving Procedures section for details.
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OPERATING ON STEEP HILLS
Operating on excessively steep hills could cause an overturn. Never operate on hills too steep for the ATV or for your abilities. • Never operate a 1-up ATV on hills steeper than 25 degrees.
STALLING WHILE CLIMBING A HILL
Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. • Always maintain a steady speed when climbing a hill.
• Always move the 4X4 switch to ADC (if equipped) before ascending or descending a hill.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A passenger should also lean uphill.
• Apply the brakes. • Lock the parking brake when fully stopped. • Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. Have a passenger dismount first, then the operator may dismount. • Turn the ATV around and remount, following the procedure described in the owner's manual.
If the ATV begins rolling downhill:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the hand brake gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. Have a passenger dismount first, then the operator may dismount.
• Turn the ATV around and remount, following the procedure described in the owner's manual.
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OPERATING ON SLIPPERY TERRAIN
Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the vehicle on such terrain.
Always use extra caution on rough, slippery or loose terrain.
OPERATING IN UNFAMILIAR TERRAIN
Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
IMPROPER TIRE MAINTENANCE
Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.
Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure as described in the owner's manual and on safety labels.
OPERATING IMPROPERLY IN REVERSE
Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See the New Operator Driving Procedures section for details.
Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.
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OPERATING OVER OBSTACLES
Improperly operating over obstacles could cause loss of control or rollover.
Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See the New Operator Driving Procedures section for details.
SKIDDING OR SLIDING
Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.
Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See the New Operator Driving Procedures section for details.
OPERATING A DAMAGED VEHICLE
CAUTION Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle, and steering systems.
OPERATING THROUGH WATER
Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle.
Always follow proper procedures for operating in water as described in this
Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
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IMPROPER CARGO LOADING
Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident.
• Always follow the instructions in this owner’s manual for carrying cargo.
• Never exceed the stated load capacity for this vehicle.
• Cargo should be properly distributed and securely attached.
• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
OPERATING ON FROZEN BODIES OF WATER
Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.
Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.
POOR VISIBILITY
CAUTION Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
PHYSICAL SKILLS
Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control.
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HOT EXHAUST SYSTEMS
WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
Use caution when traveling through tall grass, especially dry grass, and when traveling in muddy conditions. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush, other tall ground cover, and muddy conditions. Promptly remove any grass, debris, or foreign matter clinging to the vehicle. Pay particular attention to the exhaust system area.
UNAUTHORIZED USE OF THE VEHICLE
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.
EQUIPMENT MODIFICATIONS
Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.
Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.
FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.
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TRAILER HITCH WARNING (IF EQUIPPED)
Trailering with a Polaris Scrambler is not recommended. If trailering, read and understand the warning below. WARNING When trailering with your ATV, be aware that the exhaust is located above the hitch ball receiver and the trailer hitch. During operation of the ATV, the exhaust will produce hot exhaust gas that should not be inhaled and that may elevate the surface temperature of surrounding surfaces, including trailer surfaces (e.g., trailer hitch, trailer tongue, trailer walls, . . . etc.). To reduce the risk of inhaling exhaust gases and to avoid risk of burn or injury, shut off your engine and allow time for the exhaust gases to dissipate and for the surfaces surrounding the exhaust to cool, including the trailer surfaces, before connecting or disconnecting a trailer. To reduce the potential for the trailer hitch or trailer tongue from getting too hot, do not use a receiver hitch with a rise of more than two inches.
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SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
q General Warning w Reverse Override Warning e Age Warning r 4x4 Caution t Clutch Warning (Under Seat) y “No Passenger” Warning u Tire Pressure/Load Warning i Rack Warning 23
GENERAL WARNING
WARNING
Improper use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper training or instruction • at speeds too fast for your skills or the conditions • on public roads - a collision can occur with another vehicle • with a passenger - passengers affect balance and steering and increase risk of losing control
ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns • avoid paved surfaces - pavement may seriously affect handling and control LOCATE AND READ OWNER’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
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TIRE PRESSURE/LOAD WARNING
WARNING
Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.
• Cold tire pressure: – Front: 7.0 psi (48.3 kPa) – Rear: 7.0 psi (48.3 kPa) • Maximum weight capacity: 290 lbs. (131 kg) • Lug nut torque values: 120 ft-lbs. (163 Nm)
RACK/BOX WARNING
WARNING
• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.
• Maximum Rack Loads: Front 25 lbs. (11 kg) Rear 50 lbs. (23 kg)
4X4 (AWD) CAUTION
CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.
“NO PASSENGER” WARNING
WARNING
NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.
DISCRETIONARY WARNING
WARNING
• Never operate this ATV on HILLS steeper than 25 degrees 25°. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.
• REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.
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AGE 16 WARNING
The Age 16 warning is located on the left-hand wheel well.
WARNING
Operating this ATV if you are under the age of 16 increases your chance of severe injury or death.
NEVER operate this ATV if you are under age 16.
REVERSE OVERRIDE WARNING
WARNING
Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.
CLUTCH COVER WARNING
WARNING
• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
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FEATURES AND CONTROLS CONTROLS
q Key Ignition Switch w Engine Stop Switch e Mode/Reverse Override Switch r Headlight Switch t 4x4 Switch y Throttle Lever u Throttle Performance Switch i LED Light Switch
IGNITION SWITCH/LIGHT SWITCH
Use the ignition switch to start the engine. The key can be removed from the switch when it is in the OFF position.
OFF RUN START Turn the key to the OFF position to stop the engine. Electrical circuits are off.
Turn the key the RUN position to activate electrical components. Electrical circuits are on. Electrical equipment can be used. Turn the key to the START position to engage the electric starter. See the Starting the Engine section for starting procedures.
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ENGINE STOP SWITCH
Move the stop switch right to the OFF position to stop the engine quickly. w vehicle, including lights.
either left or Move the stop switch to the RUN position before attempting to start the engine. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electrical power to the
MODE/REVERSE OVERRIDE SWITCH
WARNING Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button.
This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button e . The reverse override button also acts as a MODE button when held down for approximately one half second. The override button will not function as a MODE button if the transmission is in reverse.
HEADLIGHT SWITCH
Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position.
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4X4 SWITCH (IF EQUIPPED)
The drive mode switch t controls the All Wheel Drive (AWD/4X4) system. Use this switch to engage AWD (4X4) or 2X4. The vehicle automatically engages 4X4 when operating in reverse if the drive mode is set to AWD (4X4).
See page 36 for drive mode (AWD)
operating instructions.
THROTTLE LEVER
WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the throttle control system or replace it with any after market throttle mechanisms.
Engine speed and vehicle movement are controlled by pressing the throttle lever y . The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle.
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BRAKE LEVER
WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever q toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your POLARIS dealer or other qualified service facility for proper diagnosis and repairs.
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PARKING BRAKE
LOCKING THE PARKING BRAKE
WARNING Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.
1. Place the transmission in PARK.
2. Squeeze and release the brake lever q two or three times, then squeeze and hold.
3. Push the parking brake lock w forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
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MASTER CYLINDER/BRAKE FLUID
WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master cylinder before each ride.
1. Position the ATV on a level surface.
2. Position the handlebars so the master cylinder q is level.
3. View the brake fluid level through the indicator window the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.
w on the top of 4. If the fluid level is low, remove the cover screws and add fluid to the fill line.
Do not overfill.
Use DOT 4 brake fluid only.
5. Reinstall the cover. Torque screws to 7 in-lbs (.8 Nm).
32
AUXILIARY FOOT BRAKE
WARNING Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.
If the rear wheels slide while using the auxiliary brake,
reduce
q brake pedal pressure to brake the rear wheels .
without skidding.
BRAKE FLUID LEVEL
Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the front storage box.
Maintain the fluid level between the maximum and minimum marks. Use DOT 4 brake fluid only.
33
AUTOMATIC TRANSMISSION GEAR SELECTOR
The transmission gear selector located on the right side of the vehicle.
H: L: N:
High Gear Low Gear Neutral q is
R:
Reverse
P:
Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.
NOTE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.
BELT LIFE
To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.
FUEL CAP
NOTICE
Never use fuel blends with more than 10% ethanol. Engine damage could occur.
Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.
Remove the fuel tank cap q fuel. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M)/2 octane.
use fuel with ethanol content greater than 10%, such as E-85 fuel.
and add The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.
Do not
34
FRONT COMPARTMENT
To gain access to the front compartment, release the front rack latches 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.
q and remove the rack. To
Access the following components in the front compartment: • Radiator cap • Brake fluid reservoir • Battery • Coolant recovery bottle cap • Electrical/fuse/relay components q Radiator Cap w Coolant Bottle Cap e Electrical/Fuse/Relay r Battery t Brake Fluid Reservoir 35
ELECTRONIC POWER STEERING (EPS)
Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information.
ALL WHEEL DRIVE SYSTEM
The All Wheel Drive system is controlled by the Drive Line switch.
4X4 MODE
When the switch is on 4X4, the ATV is four-wheel drive, and the 4X4 indicator icon in the instrument cluster display will be visible.
When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.
2X4 MODE
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
ENGAGING 4X4
The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3000. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.
Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.
NOTICE
Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.
36
INSTRUMENT CLUSTER
OVERVIEW
NOTICE
The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
q w e r
Gear Indicator Display Area 2 Display Area 1 Fuel Gauge
t
Service Indicator
y
Clock
u
AWD Indicator
H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park – = Gear Signal Error (or shifter between gears) This area displays odometer, trip meter, trip meter 2, voltage, engine temperature, engine hour meter, programmable service hour interval, ground speed, or engine RPM.
This area displays engine RPM, ground speed, or coolant temperature.
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.
A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled
maintenance. See page 49 for more information.
The clock displays time in a 12-hour or 24-hour format.
Segments of the indicator illuminate based on drive mode engaged.
37
INDICATOR LAMPS
q Check Engine w EPS Warning (if equipped) e Engine Hot r Neutral t Helmet/Seat Belt y High Beam u Chassis Fault i Performance Limited 38 This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist.
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.
This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating condition exists.
This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a reminder to wear helmet and seat belt (if equipped) before operating.
This lamp illuminates when the headlamp switch is set to high beam.
If applicable.
On models equipped with a low speed limiter, indicator light will remain on when low speed limiter is active.
DIGITAL GAUGE
The instrument cluster displays critical vehicle information to the user.
NOTE Some features are not applicable to all models. The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including 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.
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 1 -
This area displays engine RPM, ground speed, or coolant temperature.
3.
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.
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
more information.
- A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See the Periodic Maintenance Chart section for 6.
Clock -
The clock displays time in a 12-hour or 24-hour format.
7.
AWD Indicator
- Segments of the indicator illuminate based on drive mode engaged.
39
DISPLAY AREA 1
Pressing the MODE button will change the information displayed in Area 1 q .
Speed Engine Temperature RPM Ambient Temperature (Optional) 40
DISPLAY AREA 2
Toggle the Up/Down buttons to change the information displayed in Area 2 w . Odometer Engine Temperature Trip 1 Ambient Temperature (Optional) 41
Trip 2 RPM Voltage Engine Hours Speed Service Hours 42
OPTIONS MENU
Press and hold the MODE button to enter the Options Menu.
OPTIONS MENU
Diagnostic Codes Units - Distance Units - Temp Clock Backlight Color Backlight Level Service Hours Bluetooth Pairing Exit Menu
NOTES
Only displays if fault codes are present or stored Select MPH or KPH Select between °F and °C Select between 12H or 24H, and set time Select between Blue or Red Set backlight brightness level View/Set Service hours Pair Bluetooth device Exit 43
UNIT SELECTION DISTANCE
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Units-Distance” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (MPH or KPH) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
44
UNIT SELECTION TEMPERATURE
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Units - Temp” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (°F or °C) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
45
CLOCK
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Clock” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (12H or 24H) e With the correct unit displayed, Press the mode button which will set the unit.
r Toggle the Up/Down Buttons to change the units (Cycles Hours) t With the correct unit displayed, Press the mode button which will set the unit.
y Toggle the Up/Down Buttons to change the units (Cycles 10s of Minutes) u With the correct unit displayed, Press the mode button which will set the unit.
i Toggle the Up/Down Buttons to change the units (Cycles 1s of Minutes) o With the correct unit displayed. Press the mode button which will set the unit and return to the Options menu.
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
46
BACK LIGHT COLOR
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Backlight Color” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (Blue or Red) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
47
BACK LIGHT LEVEL
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Backlight Level” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (Increase or De crease Level) e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu. 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
48
SERVICE HOURS
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Service Hours” from the Options Menu by pressing the MODE button. Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100) e With the correct unit displayed, press the MODE button, which will set the unit and return you to the Options Menu.
NOTICE
To reset service hours after they have counted down to "0.0", reselect the existing setpoint or select a new service hour value.
3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
BLUETOOTH OPERATION (IF EQUIPPED)
The Bluetooth functionality allows users to pair their phones with the vehicle’s digital gauge. This function allows users to receive call and text alerts while operating the vehicle.
PAIRING YOUR PHONE TO THE DIGITAL GAUGE
Use the following procedure to pair your phone with the vehicle’s digital gauge.
49
NOTE Bluetooth functionality is compatible with both iOS and Android phones. For iOS phones, you must go to the Settings option and enable notifications. Most Android phones will prompt the user automatically to enable notifications as part of the pairing process.
1. Make sure Bluetooth is enabled on your phone.
2. Access the options menu on the vehicle’s digital gauge and select
BT PAIR
. The Bluetooth icon will begin to blink.
3. Find and select you exit the
Polaris Gauge
prompt. Pairing should occur momentarily. Pairing mode will
BT PAIR
menu.
on your phone’s Bluetooth menu or continue for up to 90 seconds or if After successfully pairing the phone, the vehicle’s digital gauge will automatically reconnect with the phone each time it is powered on and within range. No further action is required by the user at this point.
NOTE Once the digital gauge is powered off, Bluetooth connectivity will cease. Also, when a new phone is paired with the digital gauge, all missed call and text information from the previous phone will be erased. Up to 16 different phone pairings can be saved to the digital gauge. The digital gauge does not support systems below Android version 4.2 and iOS version 8.4.
SAFEGUARDS
• If a text message is received while the vehicle is moving faster than 2 KPH, only the sender’s name is shown onscreen.
• If you are browsing any of the Bluetooth menus and the vehicle starts to move faster than 2 KPH, the menu will automatically display
VEHICLE MOVING
.
• If you attempt to access Bluetooth menus while the vehicle is moving faster than 2 KPH, the screen will display
VEHICLE MOVING
momentarily, and then it will redirect to the options menu.
50
DIAGNOSTIC CODE
NOTICE
Diagnostic Code Screen will show available MIL that has come on during that ignition cycle.
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu item.
2. Select “Diagnostic Codes” from the Options Menu by pressing the MODE button. Toggle the Up/Down Buttons to cycle through Code(s).
NOTICE
This option will only be available if a fault code was set or is active during the current ignition key 'on' cycle. Turning off the ignition will clear any save fault codes from the gauge.
Reference the image shown above: q Area A will Display FMI (XX) w Area B will Display SPN (XXXXXX) e Clock Area will Display Count (XXX) 3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.
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.
51
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.
COMPONENT
Throttle Position Sensor Engine Temperature Sensor Intake Air Temperature Sensor Manifold Absolute Pressure Sensor Crankshaft Position Sensor Vehicle Speed Signal Gear Sensor Signal Injector 1 (MAG) (SDI Part Load)
DIAGNOSTIC CODES CONDITION SPN
Voltage Too High 51 Voltage Too Low 51 Voltage Too High 110 Voltage Too Low 110 Temperature Too High 110 Engine Overheat Shutdown Voltage Too High 110 105 Voltage Too Low 105 Voltage Too High 102 Voltage Too Low 102 Signal Out of Range 102 Circuit Fault Plausibility Fault 636 636 Speed Too High 84 Plausibility Fault 84 Voltage Too Low 523 Voltage Too Low 523 Signal Fault 523 Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded 651 651 651 0 5 3 4 3 2 8 2 4 3 4 3 4 2 8 2
FMI
3 4 3 4 16 52
COMPONENT
Injector 2 (PTO) (SDI Part Load) Ignition Coil Primary Driver 1 (MAG) Ignition Coil Primary Driver 2 (PTO) Fuel Pump Driver Circuit Fan Relay Driver Circuit Idle Air Control Starter Enable Circuit Chassis Relay
DIAGNOSTIC CODES CONDITION SPN
Driver Circuit Open/ Grounded 652 Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Short to B+ 652 652 1268 Driver Circuit Short to B+ Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Position Out of Range 1269 1347 1347 1347 1071 1071 1071 634 634 634 634 Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Driver Circuit Open/ Grounded 1321 1321 1321 520208
FMI
5 3 4 3 3 5 3 4 5 3 4 5 3 4 7 5 3 4 5 53
COMPONENT
All Wheel Drive Control System Power Throttle Safety Signal Active Descent Control System Idle Speed
DIAGNOSTIC CODES CONDITION SPN
Driver Circuit Short to B+ 520208 Driver Circuit Grounded 520208 Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Voltage Too High 520207 520207 520207 168 Voltage Too Low 168 Voltage Too High 520194 Voltage Too Low 520194 Signal Out of Range 520194 Throttle Stuck Driver Circuit Open/ Grounded Driver Circuit Short to B+ Driver Circuit Grounded Speed Too High 520194 520203 520203 520203 520211 Speed Too Low 520211
COMPONENT
Vehicle Speed Sensor
DIAGNOSTIC CODES CONDITION SPN EPS MODELS ONLY
Data Valid But Above Normal Operational Range - Most Severe Level 84 54
FMI
3 4 5 3 4 3 4 3 4 3 4 3 4 2 7 5
FMI
0
COMPONENT
System Power
DIAGNOSTIC CODES CONDITION SPN EPS MODELS ONLY
Data Erratic, Intermittent Or Incorrect 84 Abnormal Rate Of Change 84 Received Network Data In Error Data Valid But Above Normal Operational Range - Most Severe Level Voltage Above Normal, Or Shorted To High Source 84 168 168 Engine Speed ECU Memory Voltage Below Normal, Or Shorted To Low Source Data Valid But Above Normal Operational Range - Most Severe Level Data Erratic, Intermittent Or Incorrect Received Network Data In Error Bad Intelligent Device Or Component Calibration Out Of Calibration Out Of Calibration Steering Over Current Shut Down Current Above Normal Or Grounded Circuit Steering Excessive Current Error Steering Torque Partial Failure Steering Torque Full Failure Current Above Normal Or Grounded Circuit Condition Exists Condition Exists 168 190 190 190 628 628 630 520221 520222 520223 520224
FMI
2 10 19 0 3 4 0 2 19 12 13 13 6 6 31 31 55
COMPONENT
EPAS Inverter Temperature EPAS Communications Receive Data Error Position Encoder Error EPAS Software Error EPAS Power Save Condition EPS SEPIC Voltage Error
DIAGNOSTIC CODES CONDITION SPN EPS MODELS ONLY
Data Valid But Above Normal Operational Range - Most Severe Level 520225 Data Valid But Above Normal Operating Range - Moderately Severe Level Data Erratic, Intermittent Or Incorrect Condition Exists 520225 520226 520226 Root Cause Not Known 520228 Bad Intelligent Device Or Component 520228 Condition Exists Bad Intelligent Device Or Component Condition Exists Condition Exists 520228 520229 520229 520231 Voltage Above Normal, Or Shorted To High Source Voltage Below Normal, Or Shorted To Low Source 524086 524086
FMI
0 16 12 31 12 31 31 2 31 11 3 4 56
OPERATION IMPORTANT INFORMATION
WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.
VEHICLE BREAK-IN PERIOD
The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.
NOTICE
Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.
Use of any improper oils may cause serious engine damage. POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle engine.
57
ENGINE AND DRIVETRAIN BREAK-IN
1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always exercise extreme caution whenever handling gasoline.
2. Check the oil level. See the Oil Check section for reference. Add the recommended oil as needed to maintain the oil level in the safe operating range.
3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.
8. During the break-in period, change both the oil and the filter at 25 hours or one month.
9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.
BRAKE SYSTEM BREAK-IN
Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.
PVT BREAK-IN (CLUTCHES/BELT)
A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt.
58
PRE-RIDE CHECKLIST
Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
ITEM
Brake system/lever travel Brake fluid Auxiliary brake Front suspension Rear suspension Steering Tires Wheels/fasteners Frame nuts, bolts, fasteners Fuel and oil Coolant level Coolant hoses Throttle Indicator lights/switches Engine stop switch Air filter, pre-filter Headlamp Brake light/taillight Riding gear Winch (if equipped) Grass and Leaves
REMARKS
Ensure proper operation Ensure proper level Ensure proper operation Inspect, lubricate if necessary Inspect, lubricate if necessary Ensure free operation Inspect condition and pressure Inspect, ensure fastener tightness Inspect, ensure tightness Ensure proper levels Ensure proper level Inspect for leaks Ensure proper operation Ensure operation Ensure proper operation Inspect, clean Check operation Check operation Wear approved helmet, goggles, and protective clothing Inspect cable and switch Remove grass, leaves, foreign matter, and other flammable material or debris, especially near the exhaust system
PAGE
-
-
-
-
59
SAFE OPERATION PRACTICES
1. Complete the recommended safety training before operating this vehicle.
Visit www.atvsafety.org for safety courses and riding tips. See page 11 for
details.
2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
3. Never carry a passenger on a 1-up ATV. Never carry more than one passenger on a 2-up ATV.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.
5. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable).
6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.
7. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
8. Drive in a manner appropriate for your skills, your passenger’s skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
9. Never consume alcohol or drugs before or while operating an ATV.
10. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.
11. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.
12. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party.
13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
60
TRAIL ETIQUETTE
Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.
KNOW YOUR RIDING AREA/TREAD LIGHTLY
Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.
STARTING THE ENGINE
1. Position the vehicle on a level surface outdoors or in a well- ventilated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
TIP The starter interlock will prevent the engine from starting if the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
TIP Do not press the throttle while starting the engine.
5. Turn the ignition key past the ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.
6. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.
61
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.
NEW OPERATOR DRIVING PROCEDURES
1. Wear protective riding gear. See the Safe Riding Gear section.
2. Perform the pre-ride inspection.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
62
TURNING THE VEHICLE
Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down.
2. Never turn quickly when carrying cargo.
3. Steer in the direction of the turn.
4. Keep both feet on the footrests.
5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.
6. Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.
DRIVING ON SLIPPERY SURFACES
Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE
Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.
4. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.
5. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
63
DRIVING UPHILL
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
2. Drive straight uphill.
3. Avoid steep hills. Maximum incline is 25° 4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with excessively slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill.
8. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards.
9. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.
10. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.
64
DRIVING DOWNHILL
When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
3. Avoid steep hills. Maximum incline is 25° 4. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
5. Slow down. Never travel down a hill at high speed.
6. Drive straight downhill. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.
7. Shift body weight uphill.
8. Apply the brakes
slightly
to aid in slowing. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.
65
DRIVING ON A SIDEHILL (SIDEHILLING)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a sidehill is
unavoidable
, follow these precautions: 1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.
4. If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side
immediately
!
TURNING AROUND ON A HILL (K-TURN)
If the vehicle stalls while climbing a hill, never back it down the hill! Use the K- turn to turn around. 1. Stop and lock the parking brake while keeping body weight uphill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See the Switch Location section for details.
3. Leave the transmission in forward and shut off the engine.
4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill. Start the engine with the transmission still in forward.
8. Release the parking brake and proceed
slowly
, controlling speed with the brake lever, until the vehicle is on more level ground.
66
DRIVING THROUGH WATER
Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water.
2. Choose a crossing where both banks have gradual inclines.
3. Avoid operating through deep or fast-flowing water.
NOTICE
Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the Periodic Maintenance Chart. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings. If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle Immersion section of this manual, and take the vehicle in for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
If it’s unavoidable to enter water deeper than the footrest level:
• Proceed slowly. Avoid rocks and obstacles.
• Balance your weight carefully. Avoid sudden movements.
• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes.
67
DRIVING OVER OBSTACLES
Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or fallen trees.
5. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.
68
DRIVING IN REVERSE
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes
lightly
for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.
NOTICE
Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.
69
PARKING ON AN INCLINE
Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
STOPPING THE ENGINE
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the key to the OFF position.
4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.
WARNING A rolling vehicle can cause serious injury. Always place the transmission in PARK before stopping the engine. 70
PARKING THE VEHICLE
1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Engage the parking brake (if equipped).
5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.
6. Remove the ignition key to prevent unauthorized use.
CARGO WARNING
WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.
71
WARNING OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
The vehicle should never exceed 10 mph (16 kph) while towing a load on a level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.
HAULING CARGO
When hauling cargo, adhere to the following: 1. Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual 2. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
3. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
4. Do not obstruct the headlight beam with cargo.
5. Slow down.
6. Use low forward gear when hauling or towing heavy cargo to extend belt life.
7. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling and control may be affected.
72
TOWING LOADS
IMPORTANT Trailering with a Polaris Scrambler is not recommended. If trailering, ensure the receiver does not exceed a two inch drop or raise.
Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE
Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.
MAXIMUM TOWING CAPACITIES
Do not exceed maximum towing capacities. Avoid towing on inclines. Maximum Towed Load (Level Ground) 1500 lbs. (680 kg) Maximum Vertical Hitch Weight 150 lbs. (68 kg) 73
74
WINCH GUIDE WINCH SAFETY
These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.
WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.
WINCH SAFETY PRECAUTIONS
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the winch.
5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the
Shock Loading
7. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.
11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.
75
12. If winching at an angle is unavoidable, follow these precautions: a. Look at the winch drum occasionally. Never let the winch cable “stack” or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s rated capacity.
15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the winch cable while winching a load.
17. Never let the winch cable run through your hands, even if wearing heavy gloves.
18. Never release the clutch on the winch when the winch cable is under load.
19. Never use the winch for lifting or transporting people.
20. Never use the winch to hoist or suspend a vertical load.
21. Always inspect your winch and winch cable before each use.
76
22. Never winch the hook fully into the winch. This can cause damage to winch components.
23. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.
24. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.
WINCH OPERATION
Read the Winch Safety Precautions in the preceding pages before using your winch.
TIP Consider practicing the operation and use of your winch before you actually need to use it in the field.
WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use.
Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly.
Promptly replace any worn or damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
3. Always apply your vehicle’s park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.
77
4. Always use the hook strap when handling the hook.
WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY.
• Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
78 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
• Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified dealer.
• If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
• If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly® (treadlightly.org).
• Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.
• Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
79
8. Read and adhere to the following information for winch damping to ensure safe winch use.
a. In order to absorb energy that could be released by a winch cable failure, always place a “damper” on the winch cable. A damper can be heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
b. Lay the damper on top of the mid-point of the winch cable length that is spooled out.
c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
d. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a
second stuck vehicle. See the Shock Loading section on page 83. 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.
80
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.
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.
81
WINCH CABLE CARE
WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable.
A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.
A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.
A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown below). Promptly discontinue use of a winch cable in this condition. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.
82
SHOCK LOADING
WARNING Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.
WARNING SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.
4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.
83
WINCH MAINTENANCE AND SERVICE SAFETY
WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other qualified person.
5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.
WARNING Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.
84
EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
OPERATION ON PUBLIC LANDS IN THE U.S.A.
Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at
www.gpoaccess.gov/ecfr/
.
CRANKCASE EMISSION CONTROL SYSTEM
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.
EXHAUST EMISSION CONTROL SYSTEM
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
The emissions label is located on the right front frame of the vehicle.
ELECTROMAGNETIC INTERFERENCE
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of UN ECE Regulation 10.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
85
86
MAINTENANCE PERIODIC MAINTENANCE CHART
Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with emission controls is prohibited by federal law.
Owners are responsible for performing the scheduled maintenance identified in this owner’s manual.
Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.
Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer, or other qualified person. Equivalent parts may be used for emissions-related service.
Service and adjustments are important for proper vehicle operation. If you’re not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations.
Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.
SEVERE USE DEFINITION
• Frequent immersion in mud, water or sand • Frequent or prolonged operation in dusty environments • Short trip cold weather operation • Racing or race-style high RPM use • Prolonged low speed, heavy load operation • Extended idle Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.
87
MAINTENANCE INTERVAL CHART
WARNING Improperly performing the procedures marked with a
D
could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.
SYMBOL XU D DESCRIPTION
Perform these procedures more often for vehicles subjected to severe use.
Have an authorized Polaris dealer or other qualified person perform these services.
Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log.
ITEM XU
Steering Front Suspension Rear Suspension Tires Brake Fluid Level Brake Lever Travel Brake System Wheels / Fasteners CV Boot Frame Fasteners Engine Oil Level Winch (if equipped) Air Filter (Pre- Filter) Air Box Sediment Tube
MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS CALENDAR MILES (KM) REMARKS
Pre-Ride Daily Daily Inspect and make adjustments as needed.
Inspect; clean often; replace as needed Drain deposits when visible Coolant Head Lights / Tail Lights Power Steering unit (If equipped) Daily Daily Daily Check level daily, change coolant every two years Check operation; apply dielectric grease if replacing Inspect daily, clean often 88
ITEM XU XU D
Brake Pad Wear
XU XU XU XU XU D XU XU XU
Air Filter (main element) Battery Fuel System Engine Oil Change Demand Drive Fluid Rear Gearcase Oil Transmission Fluid General Lubrication Shift Linkage Steering
XU XU
Front/Rear Suspension Throttle Release Switch Throttle Body Intake Duct Drive Belt Cooling System Radiator Cooling Hoses Oil lines and fasteners
XU
Engine oil change
XU
Demand drive fluid (normal use)
MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS CALENDAR MILES (KM)
Weekly -
REMARKS
Inspect; replace as needed 10 H 20 H 20 H 25 H 25 H 25 H 25 H 50 H 50 H 50 H 50 H 50 H 50 H 50 H 50 H 50 H 50 H 100 H 100 H 100 H Monthly Monthly Monthly 1 M 1 M 1 M 1 M 3 M 3 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 6 M 12 M 100 (160) 200 (320) Inspect periodically Check terminals; clean; test Turn key on to pressurize fuel pump, check lines/fittings for leaks and abrasion.
Break-in oil and filter change 250 (400) 250 (400) 250 (400) 500 (800) 500 (800) 500 (800) 500 (800) 500 (800) 500 (800) Break-in fluid level check Break-in fluid level check Break-in fluid level check Lubricate all fittings, pivots, cables, etc.
Inspect Lubricate Lubricate 500 (800) Inspect; adjust; lubricate; replace if necessary Inspect ducts for proper sealing / air leaks Inspect ducts for proper sealing / air leaks. Inspect belt and replace as needed.
Inspect coolant strength seasonally; pressure test system yearly 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) 1000 (1600) 600 (1000) Inspect; clean external surfaces Inspect for leaks Inspect for leaks and loose fittings Change the oil and filter Change fluid 89
ITEM XU
Rear gearcase oil
XU D XU XU XU D D D XU XU D
Transmission oil Fuel System Engine Mounts Exhaust Pipe / Silencer Spark Plug Wiring Clutches (Drive/ Driven) Wheel Bearings Brake Fluid Spark Arrestor Coolant Valve Clearance Toe Adjustment Headlight Aim
MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS CALENDAR MILES (KM)
100 H 12 M 600 (1000) Change fluid
REMARKS
100 H 12 M 600 (1000) Change fluid 100 H 12 M 600 (1000) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/ rail and fuel pump 100 H 100 H 100 H 12 M 12 M 12 M 1000 (1600) 1000 (1600) 600 (1000) Inspect Inspect Inspect; replace as needed 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc. 100 H 100 H 200 H 300 H 12 M 12 M 24 M 36 M 1000 (1600) 1000 (1600) 2000 (3200) 3000 (4800) Inspect; clean; replace worn parts Inspect; replace as needed Change every two years Clean out; or remove clean out plug 60 M Replace coolant (50/50 Extended Life Coolant) 500 H 5000 (8000) Inspect; adjust as needed Inspect periodically; adjust as needed Adjust as needed 90
LUBRICATION GUIDE
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart. Items not listed in the chart should be lubricated at the General Lubrication interval.
The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
ITEM
Engine Oil
RECOM MENDED LUBRICANT
PS-4 5W-50 4-Cycle Oil Transmission Oil AGL Gearcase Lubricant & Transmission Fluid Demand Drive Fluid (Front Gearcase) Demand Drive Fluid Rear Gearcase Oil ATV Angle Drive Fluid (or GL5 80- 90 weight gear lube) Brake Fluid Front Prop Shaft Yoke A-Arms, Front and Rear
CAPACITY AT FLUID CHANGE
2 qt.
(1.9 l) 37 oz.
(1100 ml) 9.3 oz. (275 ml) 7.1 oz. (210 ml)
FILL PLUG TORQUE
— 10-14 ft-lbs (14-19 Nm) 8-10 ft-lbs (11-14 Nm) 10-14 ft-lbs (14-19 Nm)
DRAIN PLUG TORQUE
12 ft-lbs (16 Nm) 10-14 ft-lbs (14-19 Nm) 11 ft-lbs (15 Nm) 10-14 ft-lbs (14-19 Nm)
SEE PAGE
DOT 4 Brake Fluid U-Joint Grease POLARIS All- Season Grease — — —
Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.
Grease fittings after extreme use or if suspension becomes squeaky.
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ENGINE OIL
Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil.
Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause. Your dealer can assist.
WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.
OIL RECOMMENDATIONS
Always change the oil filter whenever changing oil.
POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.
See the Lubrication Guide section for fluid recommendations, capacities and plug torques.
NOTICE
Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.
OIL LEVEL
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Check the oil level when the engine is cold. Never check the oil with the engine running. 1. Position the vehicle on a level surface.
2. Access the oil dipstick and fill tube from the left side of the ATV q . Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall and tighten the dipstick.
4. Remove the dipstick and check the oil level 5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.
6. Reinstall and tighten the dipstick.
OIL AND FILTER CHANGE
See the fluid recommendation table for capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance
Chart beginning on page 88. Always change the oil filter whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three minutes.
3. Stop the engine.
4. Clean the area around the drain plug q .
5. Place a drain pan under the crankcase.
6. Remove the drain plug q . Allow the oil to drain completely. CAUTION Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
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7. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.
8. Reinstall the drain plug. Torque to specification.
9. Remove the oil filter cover plate w by loosening the three screws holding into place.
10. Place shop towels beneath the oil filter (available from your POLARIS dealer), turn the filter counter- clockwise to remove it.
e . Using an oil filter wrench 11. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
12. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.
13. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 3/4 turn.
14. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill.
15. Reinstall the dipstick.
16. Place the transmission in PARK.
17. Lock the parking brake.
18. Start the engine. Allow it to idle for one to two minutes.
19. Stop the engine.
20. Check for leaks.
21. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
22. Dispose of used filter and oil properly.
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TRANSMISSION OIL
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. See the Fluid Recommendation table for capacities and plug torques.
Maintain the oil level at the bottom of the fill plug hole the gearcase.
w . The fill plug is located on the right side of the ATV behind the footwell. The drain plug q is located on the bottom rear side of
OIL CHECK
1. Remove the fill plug. Check the oil level.
2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
4. Reinstall the footwell.
OIL CHANGE
1. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely.
2. Clean and reinstall the drain plug. Torque to specification.
3. Remove the fill plug. Add the proper amount of the recommended oil.
4. Reinstall the fill plug. Torque to specification.
5. Check for leaks.
6. Reinstall the footwell.
7. Dispose of used oil properly.
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FRONT GEARCASE (DEMAND DRIVE) FLUID
Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart.
Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following: • operation in ADC mode for prolonged periods • constant ADC operation on hilly or mountainous terrain • ADC is the primary mode of all-wheel-drive operation TIP If the front gearcase is making excessive noise during ADC operation, change the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service.
Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.
FLUID CHECK
1. Position the vehicle on a level surface. Remove the fill plug q . Check the fluid level.
2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
FLUID CHANGE
1. Position the vehicle on a level surface. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain plug w . Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
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REAR GEARCASE OIL
Always check and change the rear gearcase oil at the intervals outlined in the
Periodic Maintenance Chart. See page 131 for the part numbers of POLARIS
products.
The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.
Maintain the fluid level at the bottom of the fill hole threads. Do not overfill.
OIL CHECK
1. Position the vehicle on a level surface.
2. Remove the fill plug q . Check the oil level.
3. Add the recommended oil as needed to bring the level to the bottom of the fill hole threads.
Do not overfill.
4. Reinstall the fill plug. Torque to specification.
OIL CHANGE
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole w .
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.
5. Remove the fill plug. Add the proper amount of the recommended oil.
Do not overfill
.
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
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POWER STEERING UNIT (IF EQUIPPED)
If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas e thoroughly.
STEERING ASSEMBLY
The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your authorized dealer or other qualified service facility before operating the vehicle.
COOLING SYSTEM
The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the Polaris Products section for the part numbers.
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RECOVERY BOTTLE COOLANT
The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box. 1. View the fluid level in the bottle.
2. If the level is low, remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
3. Reinstall the cap.
4. Close and secure the front box and cover.
RADIATOR COOLANT
To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.
Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.
CAUTION Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.
1. Access the pressure cap under the front box. See the Front Compartment section for details.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant through the radiator filler neck.
4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.
5. Close and secure the front box and cover.
BRAKES
HAND BRAKE
The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting.
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Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.
WARNING An over-full master cylinder may cause brake drag or brake lock- up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.
The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.
1. Always keep brake fluid at an adequate level. See the Master Cylinder/Brake Fluid section for details.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness. Replace brake pads when they are worn to .030” (0.762 mm).
5. Check the security and surface condition of the disc. Clean any grease using a recommended brake cleaner or alcohol. Do not use spray lubricants or other petroleum-based products. If you discover any damage (cracks, excessive corrosion, warping) see your dealer for service before operating.
AUXILIARY FOOT BRAKE
The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system.
SEAT REMOVAL
1. Grasp one side of the seat near the rear edge.
2. Pull upward abruptly to disengage the under-seat fasteners.
3. Remove the seat.
SIDE PANEL/FOOTWELL REMOVAL
Remove the seat before removing a side panel. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob.
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TIRES
WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.
Refer to the specifications section for recommended tire type, size and pressure.
TIRE TREAD DEPTH
Always replace tires when tread depth is worn to 3 mm (1/8”) or less.
FRONT WHEEL HUB TIGHTENING
Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized dealer or other qualified service facility.
101
WHEEL REMOVAL
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly. WARNING Do not service axle nuts that have a cotter pin installed. Your authorized dealer can assist.
5. Elevate the side of the vehicle by placing a suitable stand under the foot rest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
WHEEL INSTALLATION
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
WARNING Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.
WHEEL NUT TORQUE SPECIFICATIONS
Check the wheel nut torques occasionally and when they've been loosened for service.
WHEEL TYPE
Aluminum Wheel Lug Nuts
NUT TORQUE
120 ft-lbs (163 Nm) 102
TOE ALIGNMENT
WARNING Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer or other qualified service facility.
Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/4-1/2 inch (6-12 mm).
1. Position the vehicle on a level surface.
2. Place the handlebars in a straight-ahead position.
3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straight-edge instead of string.
4. Measure the distance from the string to the rim at the front the front rim. The rear measurement should be 1/8–1/4 inch (3–6 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/4–1/2 inch (6–12 mm) toe out alignment.
q and rear w of 5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for service.
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AIR FILTER INSTALLATION
1. Remove the seat, the air box cover strap, and remove the air box cover.
2. Remove the filter.
3. Remove the fabric type pre- filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.
4. Reinstall the pre-filter over the main filter. Install a new main filter if needed.
5. Reinstall the filter into the air box.
6. Reinstall the air box cover and the seat.
FUSE REPLACEMENT
If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.
Spare fuses are provided in the fuse box. 1. Access the fuses under the front box.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Close and secure the front box and cover.
SCRAMBLER® XP 1000
SPARE 20A FAN CKT BKR 20A UN SWITCH ED 10A SPARE 20A EPS 30A ACCES SORY 20A EFI 10A DRIVE 20A FUEL PUMP 10A LIGHTS 20A CHASSIS RELAY START RELAY EPS RELAY SPARE 30A FUEL PUMP RELAY FAN RELAY EFI RELAY 104
LIGHTS
HEADLIGHT BEAM INSPECTION
Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.
The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.
1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall q . Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
3. Start the engine. Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be 2 in. (5 cm) below the mark on the wall w . Include rider weight on the seat when measuring.
5. The adjustment screw is located on the left side of the headlight pod. To adjust the beam, loosen the screw. Adjust the headlamp to the desired position, then tighten the screw.
105
HEADLIGHT BEAM ADJUSTMENT
The headlight beam can be adjusted horizontally and vertically.
Tighten or loosen one or more of the three headlight adjustment screws q to adjust the beam upward or downward or to the left or right.
HEADLAMP REPLACEMENT
If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. An authorized dealer can assist.
TAILLIGHT/BRAKELIGHT LAMP REPLACEMENT
The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly.
SPARK PLUGS
SPARK PLUG RECOMMENDATIONS
Refer to the specifications section for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.
NOTICE
Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent.
PLUG CONDITION
New Spark Plug Previously Installed Spark Plug
TORQUE SPECIFICATION
18-20 ft-lbs (24-27 Nm) 18-20 ft-lbs (24-27 Nm)
SPARK PLUG INSPECTION
Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color.
106
CAUTION A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Rotate the spark plug counter-clockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specification.
NORMAL PLUG
The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.
The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.
WET FOULED PLUG
The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or poor fuel quality.
107
VEHICLE IMMERSION
If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service.
If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.
1. Move the ATV to dry land or at the very least, to water below the footrests.
2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. If equipped, remove the air box drain plug to drain water. Reinstall the drain plug. Make sure the E-ring is on the drain plug and reinstall the drain plug.
NOTICE
Serious damage could occur if the air box drain plug is not reinstalled and tightened properly.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
NOTICE
Serious damage can occur after immersion if fluids are not changed promptly. Your POLARIS dealer can assist.
7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your POLARIS dealer can provide the required service.
8. If water has been ingested into the PVT, follow the procedure on page 111 for
drying out the PVT.
108
SPARK ARRESTER
WARNING Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
• Wear eye protection and leather work gloves.
• Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Allow components to cool sufficiently before proceeding.
Never operate without the spark arrester Periodically clean the spark arrester to remove accumulated carbon. 1. Place the transmission in PARK.
2. Remove the arrester retaining bolt and nut.
3. Remove the arrester from the end of the muffler.
4. Use non-synthetic brush to clean the arrester screen. A synthetic brush may melt if the components are warm. If necessary, blow debris from the screen with compressed air.
5. Inspect the screen for wear and damage. Replace a worn or damaged screen.
6. Reinstall the arrester.
7. Torque the bolt to 7–9 ft. lbs. (10–12 Nm).
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PVT SYSTEM
WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe: • Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.
• See your POLARIS dealer, or other qualified person, for service and repair assistance.
• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.
• Always make sure the PVT housing is securely in place during operation.
The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
On POLARIS ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed.
For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1600 - 1800 RPM. However, in high range at 3 MPH (5 km/h), the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.
110
The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).
WHEN TO USE LOW RANGE AND HIGH RANGE
CONDITION
Operating at speeds less than 7 MPH (11 km/h) Towing heavy loads Operating in rough terrain (swamps, mountains, etc.) Operating at speeds greater than 7 MPH (11 km/h)
RANGE TO USE
Low Low Low High
PVT DRYING
There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 5 seconds.
5. Allow the engine RPM to settle to idle speed, then shift the transmission to low range.
6. Test for belt slippage. If the belt slips, repeat the process. Your vehicle requires service as soon as possible, which your authorized dealer can provide.
111
BATTERY
WARNING Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
BATTERY REMOVAL
1. Access the battery under the front box.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. Lift the battery out of the ATV.
BATTERY INSTALLATION
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the instructions in the Battery Charging section before installing the battery.
112
An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your authorized dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery. 1. Ensure that the battery is fully charged.
2. Place the battery in the battery holder.
3. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.
8. Close and secure the front box and cover.
BATTERY STORAGE
Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.
POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self- discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See the Polaris Products section for the part numbers.
BATTERY CHARGING
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed and
fully charged
at the factory.
Never
pry the sealing strip off or add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage.
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WARNING An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully. 1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.6 V or higher.
2. If the voltage is less than 12.6 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.6 or greater.
3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines via the table below.
BATTERY CHARGING (SEALED BATTERY)
Always verify battery condition before and 1-2 hours after the end of charging.
STATE OF CHARGE
100% 50%-75% 25%-50% 0%-25%
VOLTAGE
12.6-12.8 volts 12.0-12.5 volts 11.5-12.0 volts 11.5 volts or less
ACTION
Conventional/Low Maintenance Battery: check after 60 days AGM Battery: check after 30 days Needs charge Needs charge AGM ONLY: needs charge with desulfating charger
CHARGE TIME (USING CONSTANT CURRENT CHARGER @ STANDARD AMPS SPECIFIED ON TOP OF BATTERY)
None required 5-11 hours At least 13 hours, verify state of charge At least 20 hours 114
BATTERY IDENTIFICATION
IMPORTANT It is important to identify the type of battery installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All Polaris ORV models include either a Conventional battery or a Low Maintenance battery.
CONVENTIONAL BATTERY
• The battery is NOT activated when packaged • Distilled water and electrolyte added as required • Removable cap plugs located on top of battery • Vent tube located on side of battery
LOW MAINTENANCE BATTERY
• Battery activated when packaged • Distilled water and electrolyte NEVER added • Non removable cap(s) located on top of battery 115
LEAD ACID CONVENTIONAL / DRY SHIPPED AGM BATTERY BEST PRACTICES
Some Polaris ORV models include either a Lead Acid Conventional battery or a Dry Shipped Absorbed Glass Mat (AGM) battery. See the Service Manual for procedures on how to activate, charge, maintain, and test a Lead Acid Conventional or Dry Shipped AGM battery.
NOTICE
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
LEAD ACID CONVENTIONAL BATTERIES
ACTIVATION NOTE A Polaris battery purchased from a Polaris dealership should be activated at time of purchase by the dealer.
• Do NOT activate the battery unless it will be put into regular service within 30 days. Bulk acid should be used to activate the battery.
• Always remove the sealing cap from the vent elbow before activating the battery. Never put the sealing cap back onto the battery. The gas pressure can cause the battery to rupture.
• Let the battery sit for 30 minutes after you add the initial electrolyte. Once absorbed, fill the battery with additional electrolyte to the upper line of the electrolyte level indicator. This is the only time that electrolyte should be added to the battery.
• Once the battery is fully charged, replace cap plugs by hand. Do NOT use a tool to install the cap plugs.
CHARGING • The battery must be fully charged before use or battery life will be significantly reduced by 10-30% of the battery's full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (
PN 2830511
) charger (or a similar charger), which can be ordered through your normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s amp-hour rating. 116
MAINTENANCE • Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, battery service life and vehicle performance may be adversely affected.
• Never add any electrolyte to the battery once the battery is in service. After the battery is initially activated, only distilled water should be added to maintain electrolyte levels.
• Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.
TESTING • If the test fails, fully charge the battery.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.
DRY SHIPPED AGM BATTERIES
ACTIVATION • Do NOT activate the battery unless it will be put into regular service within 30 days. Only use the electrolyte container supplied with the battery to activate the battery.
• Keep the electrolyte container in place for 20 minutes or longer until the container is completely empty. If necessary, gently tap the container to empty it.
• Once the battery is fully charged, replace the strip of caps by hand. Do NOT use a tool to install the strip.
CHARGING • Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger, which can be ordered through your normal parts channel.
• Nominal voltage is 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
MAINTENANCE • Never add any electrolyte or distilled water to the battery once the battery is in service.
• If you do not drive the vehicle for more than TWO weeks, maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger.
• If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger and inspect the battery every 60 days.
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TESTING • If the test fails, fully charge the battery.
• If the battery is too low to accept a charge, see the AGM Battery Charging - Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.
LOW MAINTENANCE BATTERY BEST PRACTICES
Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.
NOTICE
Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.
LEAD ACID LOW MAINTENANCE BATTERY
CHARGING • The battery must be fully charged before use or battery life will be significantly reduced by 10-30% of the battery's full potential.
• Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.
• Polaris recommends using a BatteryMINDer® 12V 1.5 AMP Convertible (
PN 2830511
) charger (or a similar charger), which can be ordered through your normal parts channel.
• Charge the battery with a charging output no larger than 10% of the battery’s amp-hour rating. MAINTENANCE • Recharge the battery to its full capacity every 30 to 60 days.
• If the battery is stored or used in a partially charged condition, hard crystal sulfation will form on the plates, reducing the efficiency and service life of the battery.
• Never add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
• Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.
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TESTING • Test the battery using the PU-50296 battery tester.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.
AGM LOW MAINTENANCE BATTERIES
CHARGING • Polaris recommends using a BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger, which can be ordered through your normal parts channel.
• Nominal voltage is 12.6–12.8 Volts when fully charged. If the voltage falls below 12.5V, charge it immediately, or the battery runs the risk of sulfation.
MAINTENANCE • Never add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.
• If you do not drive the vehicle for more than TWO weeks, maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger.
• If you plan to store the vehicle for ONE month or longer, remove the battery from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer® 2012 AGM - 2 AMP (
PN 2830438
) charger and inspect the battery every 60 days.
TESTING • If the test fails, fully charge the battery.
• If the battery is too low to accept a charge, see the AGM Battery Charging - Deeply Discharged (Below 3 Volts) procedure in the Service Manual.
• Proper load testing of the battery requires special equipment and can be performed by your dealer.
CAMBER AND CASTER
The camber and caster are non-adjustable.
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SUSPENSSION ADJUSTMENT
FRONT/REAR SPRING PRELOAD ADJUSTMENT
The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads. To adjust the preload, do the following: 1. Elevate the vehicle to allow the suspension to fully extend.
2. Turn the adjusting ring to the left to increase preload for a higher ride height. Turn the adjusting ring to the right to decrease preload for a lower ride height.
FACTORY PRELOAD SETTINGS
Scrambler XP 1000 S Front Suspension Rear Suspension 15.63 in. (39.7 cm) 15.56 in. (39.5 cm)
Follow these guidelines if you make adjustments to this suspension.
• Always return the suspension to the factory setting after the load is removed from the vehicle. The increased suspension height will negatively impact vehicle stability when operating without a load.
• Always apply the same adjustment setting to both sides of the vehicle.
• Do not increase the spring preload by more than one inch (25.4 mm) over the factory setting. • When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.
120
CROSSOVER RING ADJUSTMENT
To adjust the preload, do the following: 1. Elevate the vehicle to allow the suspension to fully extend.
2. Using the spanner tool included with the vehicle, unlock the cross-over adjustment ring.
3. Adjust cross-over ring to desired location.
4. Lock the cross-over adjustment ring.
Front Suspension
CROSSOVER RING FACTORY SETTINGS
2 in. (5 cm)
HIGH/LOW SPEED COMPRESSION ADJUSTMENT
NOTE Always adjust the clicker at least one click below full stiff (full clockwise) or shock damage will occur.
HIGH SPEED COMPRESSION (RED)
To adjust high speed compression dampening, do the following: 1. Turn the outside clicker q clockwise to increase compression damping.
2. To decrease high speed compression damping, turn the outside clicker counter-clockwise.
LOW SPEED COMPRESSION (BLACK)
To adjust high speed compression dampening, do the following: 1. Turn the inside clicker w clockwise to increase compression damping.
2. To decrease high speed compression damping, turn the inside clicker counter-clockwise.
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FACTORY CLICKER SETTINGS
Front/Rear High-Speed Suspension 8 Clicks from full Stiff Front/Rear Low-Speed Suspension 5 Clicks from full Stiff
REBOUND DAMPING ADJUSTMENT
Increase the rebound damping force by turning the adjuster clockwise to increase the stiffness. Decrease the rebound damping force by turning the adjuster counterclockwise to increase the softness. The maximum adjustment for this adjuster is the fully turned in position. The minimum adjustment is 9 clicks out from the maximum position.
FACTORY CLICKER SETTINGS
Rebound Adjuster 5 Clicks from Full Stiff
THROTTLE BODY/IDLE RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer or other qualified service facility for adjustment.
HANDLEBARS
The handlebars can be adjusted for rider preference.
WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.
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1. Remove the upper headlight pod.
2. Loosen the four handlebar bolts.
3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.
4. Torque the front two bolts to specification, then torque the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.
TORQUE
Handlebar bolts:
14 ft-lbs +/- 10% (19 Nm +/- 10%) 5. Reinstall the headlight pod.
CLEANING AND STORAGE
WASHING THE VEHICLE
NOTICE
The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: • Wheel bearings • Radiator • Transmission seals • Cab and body panels • Electrical components • Switches and controls • Fuel system components • Labels and decals If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement
safety
labels are provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
123
WASHING TIPS
• Avoid the use of harsh cleaners, which can scratch the finish.
• Do not use a power washer to clean the vehicle.
• Do not use medium to heavy duty compounds on the finish.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.
POLISHING THE VEHICLE
POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.
POLISHING TIPS
• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.
CLEANING AND STORAGE
STORAGE TIPS
NOTICE
Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.
CLEAN THE EXTERIOR
Make any necessary repairs and clean the vehicle as recommended. See the Washing the Vehicle section.
STABILIZE THE FUEL
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.
124
OIL AND FILTER
Change the oil and filter. See the Engine Oil section.
AIR FILTER / AIR BOX
Replace the air filter. See Maintenance Chapter. Clean the air box.
FLUID LEVELS
Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.
• Demand drive fluid (front gearcase) • Rear gearcase fluid (if equipped) • Transmission fluid • Brake fluid (change every two years and any time the fluid looks dark or contaminated) • Coolant (test strength/fill)
INSPECT AND LUBRICATE
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.
FOG THE ENGINE
1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 1–1.5 oz. (29.5–44 cc.) of engine oil. To access the plug holes, use a section of clear 6 mm (1/4”) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap.
Do not reinstall the cap onto the plug at this step
.
5. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
6. Reinstall the spark plug caps.
7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline.
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BATTERY MAINTENANCE
See the
Battery Storage and Battery Charging
sections for storage and charging procedures.
STORAGE AREA / COVERS
Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
TRANSPORTING THE ATV
Follow these procedures when transporting the vehicle. 1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap and seats.
5. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks or handlebars.
6. Remove the key to prevent loss during transporting.
126
SPECIFICATIONS SCRAMBLER XP 1000 S
SCRAMBLER XP 1000 S
Maximum Weight Capacity 290 lbs. (131 kg) (includes operator, cargo and accessories) Dry Weight Fuel Capacity Engine Oil Capacity Coolant Capacity Rear Gearcase Oil Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Front Rack Capacity Rear Rack Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Engine Displacement Bore x Stroke Alternator Output Compression Ratio 881 lbs. (400 kg) 5.25 gal. (20 l) 2 qts. (1.9 l) 2 qts. (1.9 l) 7.1 oz. (210 ml) 9.3 oz. (275 ml) 37 oz. (1100 ml) 25 lbs. (11.3 kg) 50 lbs. (22.7 kg) 150 lbs. (68 kg) (Rear rack load and tongue weight not to exceed 240 lbs. /109 kg) 1500 lbs. (680.4 kg) 1914 lbs. (868 kg) 82.5 in. (209.5 cm) 55 in. (140 cm) 49.5 in. (125.7 cm) 53 in. (134.6 cm) 10.6 in. (27 cm) 84 in. (213 cm) unloaded EHO952LE 952 cc 90.5 x 74 475w @1200 RPM/Peak 630w 11:1 127
Starting System Ignition System Ignition Timing Idle RPM Throttle Body/Size Spark Plug Type / Gap Lubrication System Driving System Type Front Suspension Rear Suspension Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Drive Ratio, Rear Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front/Rear Brakes, Auxiliary Brake, Parking Headlight Taillights Instrument Cluster
SCRAMBLER XP 1000 S
Electric Electronic Fuel Injection 6° +/- 5° BTDC @ 1200 RPM, Engine warm 1200 +/- 50 Mikuni Dual Bore/42 mm AUTOLITE 5682 / .030 in. (0.76 mm) Wet Sump Automatic PVT (POLARIS Variable Transmission) Dual a-arm with 9.2" (23 cm) travel Progressive rate with 10.2" (26 cm) travel H/L/N/R/P 5.034:1 4.508:1 2.367:1 3.818:1 3.7:1 27X9-12 / 7 psi (48.3 kPa) 27X9-12 / 7 psi (48.3 kPa) Single-Control Hydraulic Disc, All Wheel Foot-Activated Hydraulic Disc, Rear Wheel Hydraulic Lock, All Wheel Hi/Lo Beam on Bumper (50 watt) LED Digital 128
SCRAMBLER XP 1000 S CLUTCHING
CLUTCH SETTINGS Altitude Shift Weight Drive Spring Driven Spring
Meters (Feet) 0-1800 (0-6000) 1800+ (6000+) 23-64 1323575 23-60 5142260 42-140 Purple 7043805 Black 140-240 7045111
Helix
62SR PT 3236444 129
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POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS
PRODUCT SIZE (QUANTITY) PART NUMBER
12 oz aerosol (12) 2870791 Fogging Oil 1 qt (12) 2871517 1 qt (12) 2876244 PS-4 2 qt (8) 2877490 1 gal (4) 2876245 PS-4 Extreme Duty 1 qt (12) 2 qt (8) 2878920 2878922 1 gal (4) 2878919 1 qt (12) 2878068 AGL 1 gal (4) 2878069 Pump for Gallon Jug 3.8 l 1 qt (12) 2870465 2877922 Demand Drive 2.5 gal (2) 2877923 1 qt (12) 2880514 Antifreeze / Coolant 1 gal (6) 2880513 Grease Gun Kit, Premium All Season — 2871312 Four 3 oz packs (6) 2871322 All Season Grease 14 oz cartridge Premium Starter Grease — 3 oz tube (24) 2871423 2871460 2871515 U-Joint Grease 14 oz cartridge 2871551 Dielectric Grease (Nyogel™) Carbon Clean — 12 oz bottle (12) 2871329 2871326 16 oz (12) 2870652 Fuel Stabilizer 2.5 gal (2) DOT 4 Brake Fluid Loctite™ 565 Thread Sealant POLARIS Battery Tender™ Charger — — — 2872280 2872189 2871956 2859044 131
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TROUBLESHOOTING DRIVE BELT WEAR/BURN
POSSIBLE CAUSE
Driving onto a pickup or tall trailer in high range
SOLUTION
Use low range during loading.
Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Use low range.
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.
Use the throttle quickly and effectively.
Slow/easy clutch engagement Towing/pushing at low RPM/ low ground speed Utility use/plowing Use low range only.
Stuck in mud or snow Climbing over large objects from a stopped position Belt slippage from water or snow ingestion into the PVT system Clutch malfunction Poor engine performance Slippage from failure to warm up belt Wrong or missing belt Improper break-in Use low range only.
Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and vehicle rollover.
Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and vehicle rollover.
Dry out the PVT. Prevent water from entering the PVT intake duct. See Intake Pre-Filters for more information. Inspect clutch seals for damage if repeated leaking occurs.
An authorized dealer can assist.
Check for fouled plug or foreign material in gas tank or fuel lines. An authorized dealer can assist.
Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).
Install the recommended belt.
Always break in a new belt and/or clutch.
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ENGINE DOESN'T TURN OVER
POSSIBLE CAUSE SOLUTION
Low battery voltage Recharge the battery Loose battery connections Loose solenoid connections Loose electronic control box connections Check all connections and tighten Check all connections and tighten Inspect, clean, reinstall connectors
ENGINE TURNS OVER, FAILS TO START
POSSIBLE CAUSE
Out of fuel Water is present in fuel
SOLUTION
Refuel Drain the fuel system and refuel Old or non-recommended fuel Fouled or defective spark plug No spark to spark plug Water or fuel in crankcase Low battery voltage Mechanical failure Replace with fresh recommended fuel Inspect plug and replace if necessary Inspect plug and replace if necessary Your authorized dealer can assist Recharge the battery to 12.8 VDC Your authorized dealer can assist
ENGINE BACKFIRES
POSSIBLE CAUSE
Weak spark from spark plug
SOLUTION
Inspect, clean and/or replace spark plug Set gap to specs or replace plug Incorrect spark plug gap or heat range Old or non-recommended fuel Incorrectly installed spark plug wires Mechanical failure Loose ignition connections Water present in fuel Replace with fresh recommended fuel Your authorized dealer can assist Your authorized dealer can assist Check all connections and tighten Replace with fresh recommended fuel 134
ENGINE PINGS OR KNOCKS
POSSIBLE CAUSE SOLUTION
Poor quality or low octane fuel Replace with recommended fuel Incorrect spark plug gap or heat range Set gap to specs or replace plug
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES
POSSIBLE CAUSE SOLUTION
Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Your authorized dealer can assist Set gap to specs or replace plug Loose ignition connections Water present in fuel Low battery voltage Incorrect fuel Clogged air filter Clogged intake pre-filter Other mechanical failure Check all connections and tighten Replace with new fuel Recharge battery to 12.8 VDC Replace with recommended fuel Inspect and clean or replace Inspect and clean (with soapy water) or replace Your authorized dealer can assist
ENGINE STOPS OR LOSES POWER
POSSIBLE CAUSE SOLUTION
Out of fuel Refuel Kinked or plugged fuel vent line Water is present in fuel Inspect and replace Replace with new fuel Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Incorrect spark plug gap or heat range Your authorized dealer can assist Set gap to specs or replace plug 135
POSSIBLE CAUSE
Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Clogged intake pre-filter Other mechanical failure Overheated engine
SOLUTION
Check all connections and tighten Recharge the battery Replace with fresh recommended fuel Inspect and clean or replace Inspect and clean (with soapy water) or replace Your authorized dealer can assist Clean radiator screen and core, clean engine exterior. Your dealer can assist.
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WARRANTY LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.
This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, or other qualified person, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
REGISTRATION
At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
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WARRANTY COVERAGE AND EXCLUSIONS
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.
This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.
This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items: • Wheels and tires • Suspension components • Brake components • Seat components • Clutches and components • Steering components • Batteries • Light bulbs/Sealed beam lamps • Filters • Lubricants • Bushings • Finished and unfinished surfaces • Carburetor/Throttle body components • Engine components • Drive belts • Hydraulic components and fluids • Circuit breakers/Fuses • Electronic components • Spark plugs • Sealants • Coolants • Bearings 138
LUBRICANTS AND FLUIDS
1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
139
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.
IN THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer, or other qualified person. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer, or other qualified person, that sells the same line as your product.
OUTSIDE THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED:
If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer, or other qualified person. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.
IF YOU MOVE:
If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your product.
IF YOU PURCHASE FROM A PRIVATE PARTY:
If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
140
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Dealership contacts can be found via this website, if needed:
www.polaris.com/en-us/contact
Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.
This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 141
U.S.A. EPA EMISSIONS LIMITED WARRANTY
This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.
The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to the following systems: • Air-induction system • Fuel system • Ignition system • Exhaust gas recirculation systems The following parts are also considered emission-related components for exhaust emissions: • Aftertreatment devices • Crankcase ventilation valves • Sensors • Electronic control units 142
The following parts are considered emission-related components for evaporative emissions: • Fuel Tank • Fuel Cap • Fuel Line • Fuel Line Fittings • Clamps* • Pressure Relief Valves* • Control Valves* • Control Solenoids* • Electronic Controls* • Vacuum Control Diaphragms* • Control Cables* • Control Linkages* • Purge Valves • Vapor Hoses • Liquid/Vapor Separator • Carbon Canister • Canister Mounting Brackets • Carburetor Purge Port Connector *As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of POLARIS.
143
Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer, or other qualified person, can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.
CALIFORNIA RESIDENTS
Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50- state models available for sale in California are identified by the letter “B” in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer.
If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer Assistance: United States & Canada: 1-800-POLARIS (1-800-765-2747) French: 1-800-268-6334 144
MAINTENANCE LOG MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS
145
146
2X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4X4 (AWD) Warning . . . . . . . . . . . . . . . . . . . 25
4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4x4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Crossing Hillsides . . . . . . . . . . . . . . . . . . . . . . 16
Crossover Ring Adjustment . . . . . . . 121
A
Age 16 Warning . . . . . . . . . . . . . . . . . . . . . . . . 26
Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 125
Air Filter Installation . . . . . . . . . . . . . . . . . 104
All Wheel Drive System. . . . . . . . . . . . . . . 36
Automatic Transmission Gear
Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Auxiliary Foot Brake . . . . . . . . . . . . . 33, 100
D
Descending Hills Improperly . . . . . . . . 16
Diagnostic Display Code
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Digital Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Discretionary Warning . . . . . . . . . . . . . . . . 25
Drive Belt Wear/Burn. . . . . . . . . . . . . . . . 133
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . 69
Driving on a Sidehill (Sidehilling) . . . 66
Driving on Slippery Surfaces . . . . . . . . 63
Driving Over Obstacles . . . . . . . . . . . . . . . 68
Driving Through Water. . . . . . . . . . . . . . . . 67
Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Identification . . . . . . . . . . . . . . . . . . . . . . . . . 115
Battery Charging . . . . . . . . . . . . . . . . . . . . . . 113
Battery Installation . . . . . . . . . . . . . . . . . . . . 112
Battery Maintenance . . . . . . . . . . . . . . . . 126
Battery Removal. . . . . . . . . . . . . . . . . . . . . . . 112
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . 113
Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Bluetooth Operation . . . . . . . . . . . . . . . . . . . 49
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . 33
Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Brake System Break-in . . . . . . . . . . . . . . . 58
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
C
Camber and Caster. . . . . . . . . . . . . . . . . . . 119
Cargo Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 71
Clean the Exterior . . . . . . . . . . . . . . . . . . . . 124
Cleaning and Storage . . . . . . . . . . . . . . . 123
Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Cover Warning. . . . . . . . . . . . . . . . . 26
Cold Weather Operation. . . . . . . . . . . . . . 62
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . 98
Crankcase Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
E
Electromagnetic Interference . . . . . . . 85
Electronic Power Steering (EPS). . . 36
Emissions Limited Warranty. . . . . . . 142
Engaging 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine and Drivetrain Break-in . . . . . 58
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Engine Pings or Knocks . . . . . . . . . . . . 135
Engine Runs Irregularly, Stalls
or Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Engine Stop Switch . . . . . . . . . . . . . . . . . . . . 28
Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . 70
Engine Stops or Loses Power . . . . 135
Engine Turns Over, Fails to
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
European Vibration and Noise . . . . . . . . 9
Exhaust Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Exported Products . . . . . . . . . . . . . . . . . . . 141
Exposure to Exhaust . . . . . . . . . . . . . . . . . . 14
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 12
147
F
Failure to Inspect Before
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Fluid Part Numbers . . . . . . . . . . . . . . . . . . 131
Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 125
Front Compartment. . . . . . . . . . . . . . . . . . . . 35
Front Gearcase (Demand
Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Front Wheel Hub Tightening . . . . . . 101
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . 124
Fuse Replacement. . . . . . . . . . . . . . . . . . . 104
G
General Warning . . . . . . . . . . . . . . . . . . . . . . . 24
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
K
Know Your Riding Area/Tread
Lightly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
H
Hand Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Handling Gasoline . . . . . . . . . . . . . . . . . . . . . 14
Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Headlamp Replacement. . . . . . . . . . . . 106 Headlight Beam Adjustment. . . . . . . 106
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 28
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Beam Adjustment . . . . . . . . . . . . . 105
High/Low Speed Compression
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Hot Exhaust Systems . . . . . . . . . . . . . . . . . 21
How To Obtain Warranty
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Ignition Switch/Light Switch . . . . . . . . . 27
Improper Cargo Loading . . . . . . . . . . . . . 20
Improper Hill Climbing . . . . . . . . . . . . . . . . 16
Inspect and Lubricate . . . . . . . . . . . . . . . 125
Instrument Cluster
Back Light Color . . . . . . . . . . . . . . . . . . . . . 47
Back Light Level . . . . . . . . . . . . . . . . . . . . . 48
148
I
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Diagnostic Code. . . . . . . . . . . . . . . . . . . . . 51
Display Area 1 . . . . . . . . . . . . . . . . . . . . . . . 40
Display Area 2 . . . . . . . . . . . . . . . . . . . . . . . 41
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . 38
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 43
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Service Hours . . . . . . . . . . . . . . . . . . . . . . . . 49
Unit Selection Distance . . . . . . . . . . . . 44
Unit Selection Temperature. . . . . . . 45
J
Jumps and Stunts . . . . . . . . . . . . . . . . . . . . . . 16
L
Lead Acid Conventional
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Lead Acid Low Maintenance
Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Limited Warranty . . . . . . . . . . . . . . . . . . . . . 137
Lubricants / Service Products . . . . . 131
Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . 91
M
Maintenance Interval Chart . . . . . . . . . . 88
Maintenance Log. . . . . . . . . . . . . . . . . . . . . 145
Maintenance, Periodic . . . . . . . . . . . . . . . . 87
Master Cylinder/Brake Fluid . . . . . . . . . 32
Mode/Reverse Override Switch . . . . 28
Modifications to Vehicle . . . . . . . . . . . . . . 21
N
New Operator Driving
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
“No Passenger” Warning . . . . . . . . . . . . . 25
Noise Emission Control System . . . . 85
O
Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Oil and Filter Change. . . . . . . . . . . . . . . . . . 93
Operating at Excessive Speeds . . . . 15
Operating Improperly in Reverse. . . 18 Operating in Unfamiliar Terrain . . . . . 18
Operating on Frozen Bodies of
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating on Slippery Terrain . . . . . . . 18
Operating on Steep Hills . . . . . . . . . . . . . 17
Operating Over Obstacles . . . . . . . . . . . 19 Operating Through Water . . . . . . . . . . . . 19
Operation on Public Lands in
the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
P
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Parking on an Incline . . . . . . . . . . . . . . . . . . 70
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . 71
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 131
Periodic Maintenance Chart . . . . . . . . . 87
Physical Control of the Vehicle . . . . . 15
Physical Skills. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Polaris Products . . . . . . . . . . . . . . . . . . . . . . 131
Polishing the Vehicle . . . . . . . . . . . . . . . . 124
Poor Visibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Steering Unit (Cleaning). . . . . 98
Pre-Ride Checklist . . . . . . . . . . . . . . . . . . . . . 59
Protective Apparel . . . . . . . . . . . . . . . . . . . . . 14
PVT Break-in (Clutches/Belt) . . . . . . . 58
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
R
Rack/Box Warning . . . . . . . . . . . . . . . . . . . . . 25
Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . . 99
Rear Gearcase Oil . . . . . . . . . . . . . . . . . . . . . 97
Rebound Damping Adjustment . . . 122
Recovery Bottle Coolant . . . . . . . . . . . . . 99
Registration, Warranty . . . . . . . . . . . . . . 137
Reverse Override Warning . . . . . . . . . . 26
S
Safe Operation Practices . . . . . . . . . . . . 60
Safe Riding Gear . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Labels and Locations . . . . . . . . 23
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Training. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety, Winch Maintenance. . . . . . . . . . 84
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . 100
Shock Loading the Winch . . . . . . . . . . . . 83
Side Panel/Footwell Removal. . . . . 100
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Skidding or Sliding . . . . . . . . . . . . . . . . . . . . . 19
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . 109
Specifications
Scrambler XP 1000 S . . . . . . . . . . . . 127
Spring Preload Adjustment . . . . . . . . 120
Stabilize the Fuel . . . . . . . . . . . . . . . . . . . . . 124
Stalling While Climbing a Hill . . . . . . . . 17
Starting the Engine . . . . . . . . . . . . . . . . . . . . 61
Steering Assembly. . . . . . . . . . . . . . . . . . . . . 98
Stopping the Engine . . . . . . . . . . . . . . . . . . . 70
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
T
Taillight/Brakelight Lamp
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 106
Throttle Body/Idle RPM . . . . . . . . . . . . . 122
Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Tire Pressure/Load Warning. . . . . . . . . 25
149
Toe Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 103
Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Trailer Hitch Warning . . . . . . . . . . . . . . . . . . 22
Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . 95
Transporting the ATV. . . . . . . . . . . . . . . . 126
Turning Around on a Hill (K-
Turn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Turning Improperly. . . . . . . . . . . . . . . . . . . . . 16
U
Unauthorized Use of the Vehicle . . . 21
V
Vehicle Break-in Period. . . . . . . . . . . . . . . 57
Vehicle Identification Numbers . . . . . . . 9
Vehicle Immersion . . . . . . . . . . . . . . . . . . . 108
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . 8
Washing the Vehicle. . . . . . . . . . . . . . . . . 123
Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . 107
Wheel Installation . . . . . . . . . . . . . . . . . . . . 102
Wheel Nut Torque
Winch Cable Care . . . . . . . . . . . . . . . . . . . . . 82
Winch Maintenance and
Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . 84
Winch Operation . . . . . . . . . . . . . . . . . . . . . . . 77
Winch Safety Precautions . . . . . . . . . . . 75
Winch Shock Loading . . . . . . . . . . . . . . . . . 83
150
WARNING
Improper ATV use can result in SEVERE INJURY or Death
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER
operate:
NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL
r your skills or the conditions another vehicle with a passenger - passengers affect balance and steering and increase risk of losing control
ALWAYS
: overturns on hills and rough terrain and in turns affect handling and control SCAN CODE FOR PRODUCT AND SAFETY INFORMATION. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com
Polaris Industries Inc.
2100 Highway 55 Medina, MN 55340 Part No. 9930001 Rev 0
3
Printed in USA
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Key features
999cc ProStar engine
4x4 system
Durable steel frame
LED headlights
Electric power steering
290 lb weight capacity
Digital gauge cluster
Reverse override button
Towing capacity
Frequently asked questions
The Scrambler XP 1000 S is powered by a 999cc ProStar engine.
Yes, the Scrambler XP 1000 S features a 4x4 system for enhanced traction in challenging terrain.
The Scrambler XP 1000 S has a maximum weight capacity of 290 lbs.