Polaris Sportsman 450 / 570 Owner's Manual

2019
OWNER’S MANUAL
SPORTSMAN® 570 / SPORTSMAN® 570 EPS / SPORTSMAN® 570 SP
SPORTSMAN® 570 HD / SPORTSMAN® 570 Utility Edition
SPORTSMAN® 570 SP Hunter Edition / SPORTSMAN® 450 HO
SPORTSMAN® 450 HO EPS / SPORTSMAN® 450 HD
SPORTSMAN® 450 Utility Edition / SPORTSMAN® TOURING 570
SPORTSMAN® TOURING 570 EPS / SPORTSMAN® TOURING 570 SP
SPORTSMAN® TOURING 570 EPS / SPORTSMAN® X2 570 EPS
UTE® 570 HD / SPORTSMAN® 6x6 570
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 expect as
necessary, service your vehicle in a well-ventilated area and wear gloves
or wash your hands frequently when servicing your vehicle.
For more information go to www.P65Warnings.ca.gov/passenger-vehicle.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
2019 Owner’s Manual
Sportsman® 570
Sportsman® 570 EPS
Sportsman® 570 SP
Sportsman® 570 HD
Sportsman® 570 Utility Edition
Sportsman® 570 Hunter Edition
Sportsman® 6x6 570
Sportsman® 450 HO
Sportsman® 450 HO EPS
Sportsman® 450 HD 2x4
Sportsman® 450 Utility Edition
Sportsman® Touring 570
Sportsman® Touring 570 EPS
Sportsman® Touring 570 SP
Sportsman® X2 570 EPS
UTE® 570 HD
POLARIS®, ACE™, OUTLAW®, and SPORTSMAN® are trademarks of
POLARIS Industries Inc.
Copyright 2018 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.
9929536
WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide
family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for
the latest news, new product introductions, upcoming events, career
opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational
products. We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience
have gone into the engineering, design, and development of your POLARIS
vehicle, making it the finest machine we’ve ever produced.
•
•
•
•
•
•
Snowmobiles
SPORTSMAN® All-terrain vehicles
Low emission vehicles (LEVs)
RANGER® utility vehicles
BRUTUS® work vehicles
SLINGSHOT® three wheel
motorcycles
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•
•
•
•
RZR® sport vehicles
GEM® vehicles
INDIAN® motorcycles
POLARIS POWER® generators
POLARIS DEFENSE® combat
vehicles
• Timbersled® Snow Bikes
For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual contains
instructions for minor maintenance, but information about major repairs is
outlined in the POLARIS Service Manual and can be performed by a factory
certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total
satisfaction. Your POLARIS dealership can perform all of your service needs
during, and after, the warranty period.
3
WELCOME
4
Introduction . . . . . . .
Safety . . . . . . . . . .
Features and Controls . .
Operation . . . . . . . .
Winch Guide. . . . . . .
Emission Control Systems .
Maintenance . . . . . .
Specifications . . . . . .
POLARIS Products . . . .
Troubleshooting . . . . .
Warranty . . . . . . . .
Maintenance Log . . . .
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. 69
. 91
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. 141
. 165
. 167
. 171
. 179
5
6
INTRODUCTION
INTRODUCTION
This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
WARNING
Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. 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 and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your
local POLARIS dealer. Understand all safety warnings, precautions and
operating procedures before operating the vehicle. Keep this manual with
the vehicle.
• Never operate this vehicle without proper instruction. Take an authorized
training course. Visit www.rohva.org or call 866-267-2751.
• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16
and have a valid driver’s license to operate this vehicle.
• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.
• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.
• Complete the New Operator Driving Procedures outlined in this manual.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.
• Never permit a guest to operate this vehicle unless the guest has reviewed
the owner’s manual and all safety labels and has completed a safety training
7
INTRODUCTION
SAFETY SYMBOLS AND SIGNAL WORDS
The following signal words and symbols appear throughout this manual and on
your vehicle. Your safety is involved when these words and symbols are used.
Become familiar with their meanings before reading the manual.
DANGER
DANGER indicates a hazardous situation which, if not avoided, WILL result in
death or serious injury.
WARNING
SAFETY ALERT WARNING indicates a hazardous situation which, if not
avoided, COULD result in serious injury.
CAUTION
SAFETY ALERT CAUTION indicates a hazardous situation which, if not
avoided, COULD result in minor to moderate injury.
CAUTION
CAUTION indicates special precautions that must be taken to avoid vehicle
damage or property damage.
IMPORTANT
IMPORTANT provides key reminders during disassembly, assembly, and
inspection of components.
NOTICE
NOTICE provides key information by clarifying instructions.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
8
INTRODUCTION
EUROPEAN VIBRATION AND NOISE
The driver-perceived noise and hand/arm and whole body vibration levels of this
machinery is measured per EN 15997.
The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as
indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many
factors, including:
•
•
•
•
•
Instrument and calibration uncertainty
Variations in the machine such as wear of components
Variation of machine operators such as experience or physique
Ability of the worker to reproduce typical work during measurements
Environmental factors such as ambient noise or temperature
9
INTRODUCTION
VEHICLE IDENTIFICATION NUMBERS
Record your vehicle's identification numbers and key number in the spaces
provided. Remove the spare key and store it in a safe place. An ignition key can
be duplicated only by ordering a POLARIS key blank (using your key number)
and mating it with one of your existing keys. The ignition switch must be
replaced if all keys are lost.
The vehicle serial number q can be found stamped on lower frame rail on the
rear left-hand side of the vehicle on all models.
NOTE
The figures below are for reference only. Your model may differ slightly.
Vehicle Model Number (VIN) q
Frame VIN
Engine Serial Number w
Key Number
10
SAFETY
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 RiderCoursesm that is available
to you and your eligible family members. This training is included in the
purchase price of your ATV. You were also provided with printed materials that
explain safe operating procedures. You should review this information on a
regular basis.
If you purchased a used POLARIS ATV in the United States, you can enroll in
the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at (800) 8872887 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, longsleeve shirt, long pants, over-the-ankle boots and
seat belt (if equipped) at all times. Protective gear
reduces the chance of injury.
q Helmet
w Eye Protection
e Long Sleeves
r Gloves
t Long Pants
y Over-the-Ankle Boots
11
SAFETY
HELMET
Wearing a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds established
safety standards.
Approved helmets in the USA and Canada bear a U.S.
Department of Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear
the ECE 22.05 label. The ECE mark consists of a
circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
EYE PROTECTION
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding
this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof
helmet face shield. POLARIS recommends wearing approved Personal
Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or
CE. Make sure protective eye wear is kept clean.
GLOVES
Wear gloves for comfort and for protection from sun, cold weather and other
elements.
BOOTS
Wear sturdy over-the-ankle boots for support and protection. Never ride a
POLARIS vehicle with bare feet or sandals.
CLOTHING
Wear long sleeves and long pants to protect arms and legs.
12
SAFETY
SAFETY WARNINGS
WARNING
Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. See the OPERATION section of the owner’s
manual for proper operating procedures.
OPERATING WITHOUT INSTRUCTION
Operating this vehicle without proper instruction increases the risk of an
accident. The operator must understand how to operate the vehicle properly in
different situations and on different types of terrain.
All operators must read and understand the owner's
manual and all warning and instruction labels before
operating the vehicle.
All operators should review the safety DVD provided
with this vehicle and take a ROHVA training course
(www.rohva.org).
AGE RESTRICTIONS
This vehicle is an ADULT VEHICLE ONLY. Operation
is prohibited for anyone under 16 years of age or
anyone without a valid driver’s license.
The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and both
hands on the steering wheel (if equipped) or
handlebars.
USING ALCOHOL OR DRUGS
Operating this vehicle after consuming alcohol or
drugs could adversely affect operator judgment,
reaction time, balance and perception.
Never consume alcohol or drugs before or while
operating this vehicle.
13
SAFETY
FAILURE TO INSPECT BEFORE OPERATING
WARNING
Failure to inspect and verify that the vehicle is in safe operating condition
before operating increases the risk of an accident.
Always perform the pre-ride inspection before each use of your vehicle to
make sure it's in safe operating condition.
Always follow the inspection and maintenance procedures and schedules
described in this owner’s manual.
HANDLING GASOLINE
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
EXPOSURE TO EXHAUST
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
Operate this vehicle only outdoors or in well-ventilated areas.
PROTECTIVE APPAREL
Riding in this vehicle without wearing an approved helmet and protective eye
wear increases the risk of a serious injuries in the event of an accident.
Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.
OPERATING 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.
14
SAFETY
OPERATING ON PUBLIC ROADS
Operating this vehicle on public streets, roads or
highways could result in a collision with another
vehicle. Never operate this vehicle on any public
street, road or highway, including dirt and gravel roads
(unless designated for off-highway use).
OPERATING AT EXCESSIVE SPEEDS
Operating this vehicle at excessive speeds
increases the operator's risk of losing control.
Always operate at a speed that's appropriate for
the terrain, the visibility and operating conditions
and your skills and experience.
PHYSICAL CONTROL OF THE VEHICLE
Removing even one hand or foot can reduce ability to control the vehicle or
could cause loss of balance and ejection from the ATV.
If a person's feet are not firmly planted on the footrests, they could come into
contact with the wheels or other moving parts and lead to accident or injury.
Always keep both hands on the handlebars and both feet on the footrests of the
ATV during operation.
TURNING IMPROPERLY
Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this owner’s
manual.
Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.
15
SAFETY
JUMPS AND STUNTS
Exhibition driving increases the risk of an accident or
rollover. DO NOT do power slides, “donuts”, jumps or
other driving stunts. Avoid exhibition driving.
IMPROPER HILL CLIMBING
Improper hill climbing could cause loss of control or rollover. Use extreme
caution when operating on hills. Always follow proper procedures for hill climbing
as described in this owner's manual. See the New Operator Driving Procedures
section for details.
DESCENDING HILLS IMPROPERLY
Improperly descending a hill could cause loss of control or rollover. Always
follow proper procedures for traveling down hills as described in this owner’s
manual. See the New Operator Driving Procedures section for details.
CROSSING HILLSIDES
Driving on a sidehill is not recommended. Improper procedure could cause loss
of control or rollover. Avoid crossing the side of any hill unless absolutely
necessary.
If crossing a hillside is unavoidable, always follow proper procedures as
described in this owner's manual. See the New Operator Driving Procedures
section for details.
16
SAFETY
STALLING WHILE CLIMBING A HILL
Stalling, rolling backwards or improperly dismounting
while climbing a hill could cause a rollover.
• Always maintain a steady speed when climbing a
hill.
• Always move the 4X4 switch to 4WDC (if equipped)
before ascending or descending a hill.
If all forward speed is lost:
•
•
•
•
Lean forward to keep body weight uphill. A passenger should also lean uphill.
Apply the brakes.
Lock the parking brake when fully stopped.
Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual.
If the ATV begins rolling downhill:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the single-lever
brake gradually.
• When fully stopped, apply the rear brake as well, and then lock the parking
brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual.
17
SAFETY
OPERATING ON 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.
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.
18
SAFETY
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 ATV
Operating a damaged ATV can result in an accident. After any overturn or
accident, have a qualified service dealer inspect the entire machine for possible
damage, including (but not limited to) brakes, throttle and steering systems.
OPERATING THROUGH WATER
Operating through deep or fast-flowing water can cause loss of traction, loss of
control, rollover or accident. Never operate in fast-flowing water or in water that
exceeds the floor level of the vehicle.
Always follow proper procedures for operating in water as described in this
owner’s manual. See page 74.
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.
19
SAFETY
IMPROPER CARGO LOADING
Overloading the vehicle or carrying/towing cargo improperly may cause changes
in stability and handling, which could cause loss of control or an accident.
•
•
•
•
Always follow the instructions in this owner’s manual for carrying cargo.
Never exceed the stated load capacity for this vehicle.
Cargo should be properly distributed and securely attached.
Reduce speed when carrying cargo or pulling a trailer. Allow a greater
distance for braking.
OPERATING ON FROZEN BODIES OF WATER
Severe injury or death can result if the vehicle and/or the operator fall through
the ice. Never operate the vehicle on a frozen body of water unless you have
first verified that the ice is sufficiently thick to support the weight and moving
force of the vehicle, you and your cargo, together with any other vehicles in your
party.
Always check with local authorities and residents to confirm ice conditions and
thickness over your entire route. Vehicle operators assume all risk associated
with ice conditions on frozen bodies of water.
POOR VISIBILITY
Operating this vehicle in darkness or inclement weather could result in a
collision or accident, especially if operating on a road or street. This vehicle is
not equipped with highway-approved lights. Operate this vehicle off-road only.
Use caution and drive at reduced speeds in conditions of reduced visibility such
as fog, rain and darkness. Clean headlights frequently and replace burned out
headlamps promptly.
PHYSICAL SKILLS
Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control.
20
SAFETY
HOT EXHAUST SYSTEMS
WARNING
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system.
Use caution when traveling through tall grass, especially dry grass. Always
inspect the underside of the vehicle and areas near the exhaust system after
driving through tall grass, weeds, brush, and other tall ground cover. Promptly
remove any grass or debris clinging to the vehicle.
UNAUTHORIZED USE OF THE VEHICLE
Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.
EQUIPMENT MODIFICATIONS
Your POLARIS vehicle is designed to provide safe operation when used as
directed. Modifications to your vehicle may negatively impact vehicle stability.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may
become less stable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds.
Do not install any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.
The POLARIS limited warranty on your POLARIS vehicle will be terminated if
any non-POLARIS approved equipment and/or modifications have been added
to the vehicle that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers,
blades, tires, sprayers, or large racks, may change the handling characteristics
of the vehicle. Use only POLARIS-approved accessories, and familiarize
yourself with their function and effect on the vehicle.
FOR MORE INFORMATION ABOUT SAFETY
call POLARIS at 1-800-342-3764.
21
SAFETY
SAFETY LABELS AND LOCATIONS
Warning labels have been placed on the vehicle for your protection. Read and
follow the instructions on each label carefully. If any of the labels shown in this
manual differ from the labels on your vehicle, always read and follow the
instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your
POLARIS dealer to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge. The part number is printed on the label.
GENERAL WARNING
The General q warning is located on the left-hand side of the vehicle.
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
22
SAFETY
GENERAL WARNING (2–UP MODELS)
WARNING
Improper use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR
DRIVER AND PASSENGER
NEVER USE ON PUBLIC ROADS
NEVER CARRY MORE THAN 1 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 unless passenger seat is securely in place
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
• reduce speed and use extra caution at all times when carrying a passenger dismount passenger when conditions require
• make sure passenger reads and understands this label and passenger safety
label
23
SAFETY
NO PASSENGER WARNING (1-UP MODELS)
The “No Passenger” warning w is
located on the left-hand side of the
vehicle.
WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control,
resulting in SEVERE INJURY or
DEATH.
PASSENGER WARNING (2-UP MODELS)
WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or DEATH
NEVER CARRY MORE THAN ONE PASSENGER
NEVER RIDE AFTER USING DRUGS OR ALCOHOL
NEVER carry a passenger too small to firmly plant feet on footrests and securely
grasp hand holds.
THE PASSENGER MUST ALWAYS:
• use an approved helmet and protective gear
• securely grasp hand holds and plant feet firmly on footrests while seated in
the passenger seat
• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require
24
SAFETY
FUEL TRANSPORT / PASSENGER WARNING (6X6
MODELS)
The Fuel Transport / Passenger warning e is located in the cargo box.
WARNING
Remove flammable material containers from box before filling.
WARNING
• Passengers can be thrown off. This
can cause serious injury or death.
• Never carry passengers.
WARNING
Maximum Box Load 800 lbs.
AGE 16 WARNING
The Age 16 warning r is located on the
left-hand wheel well.
WARNING
Operating this vehicle if you are under
the age of 16 increases the chances of
severe injury or death to operator.
NEVER operate this vehicle if you are
under age 16.
25
SAFETY
AGE 16 WARNING (2-UP MODELS)
WARNING
Operating this vehicle if you are under the age of 16 increases the chances of
severe injury or death to both operator and passenger.
NEVER operate this vehicle if you are under age 16.
RACK WARNING, FRONT AND REAR
The Rack warning t can be found on
the front and rear racks.
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 90 lbs. (41
kg) Rear 180 lbs. (82 kg)
REVERSE OVERRIDE / AWD WARNING
WARNING
Improper use of override button can lead to loss of control resulting in severe
injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.
CAUTION
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
DISCRETIONARY WARNING (1–UP MODELS)
The Discretionary Warning y is located
on the right-hand wheel well.
WARNING
• Never operate this ATV on HILLS
steeper than 25 degrees. To prevent
overturn on hilly terrain, use throttle
and brakes gradually, and shift
weight uphill.
• REVERSE operation can be
dangerous even at low speeds.
Steering becomes difficult. To
prevent loss of control, avoid sudden
braking or sharp turns.
26
SAFETY
DISCRETIONARY WARNING (2–UP MODELS)
The Discretionary Warning is located on the right side of the vehicle.
WARNING
• Never operate this ATV on HILLS steeper than 15 degrees. To prevent
overturn on hilly terrain, use throttle and brakes gradually, and shift weight
uphill.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
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.
TIRE PRESSURE/LOAD WARNING (1-UP MODELS)
The Tire Pressure/Load warning u is located on the left-hand side of the
vehicle.
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 (48.2 kPa)
– Rear: 7.0 psi (48.2 kPa)
• Maximum weight capacity: 575 lbs.
(261 kg)
NEVER exceed 50 MPH (80 km/h)
when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are
above 37 lbs. (17 kg).
27
SAFETY
TIRE PRESSURE/LOAD WARNING (TOURING MODELS)
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 (48.2 kPa)
– Rear: 7.0 psi (48.2 kPa)
• Maximum weight capacity: 485 lbs. (220 kg)
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
TIRE PRESSURE/LOAD WARNING (6X6 MODELS)
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 (48.2 kPa)
– Center: 10.0 psi (68.9 kPa)
– Rear: 10.0 psi (68.9 kPa)
• Maximum weight capacity: 1115 lbs. (507 kg)
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs.
(91 kg) and/or front cargo loads are above 100 lbs. (45 kg).
4X4 (AWD) WARNING (IF EQUIPPED)
WARNING
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
28
SAFETY
INTERNATIONAL SAFETY LABELS
GENERAL WARNING (1–UP MODELS)
WARNING
Improper use can result in SEVERE INJURY or DEATH
READ AND UNDERSTAND YOUR OWNER’S MANUAL
NEVER OPERATE THIS VEHICLE IF YOU ARE UNDER AGE 16
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE WITH DRUGS OR ALCOHOL
NEVER CARRY PASSENGERS
NEVER USE ON PUBLIC ROADS
29
SAFETY
GENERAL WARNING (2–UP MODELS)
WARNING
Improper use can result in SEVERE INJURY or DEATH
READ AND UNDERSTAND YOUR OWNER’S MANUAL
NEVER OPERATE THIS VEHICLE IF YOU ARE UNDER AGE 16
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR
NEVER USE WITH DRUGS OR ALCOHOL
NEVER CARRY MORE THAN ONE PASSENGER
NEVER USE ON PUBLIC ROADS
FUEL TRANSPORT WARNING
WARNING
NEVER carry fuel or other flammable liquids on this
vehicle
Failure to follow this instruction could lead to serious
burn injuries or death.
30
SAFETY
FUEL TRANSPORT / PASSENGER WARNING (6X6 MODELS)
WARNING
Read and understand your owner’s manual
Remove flammable material containers from box before filling.
WARNING
• Passengers can be thrown off. This can cause serious injury or death.
• Never carry passengers.
Maximum Box Load 181 kg.
DISCRETIONARY WARNING (UTE MODELS)
ALERT
Rear and understand your owner’s
manual.
Never operate this ATV on HILLS
steeper than 25 degrees. To prevent
overturn on hilly terrain, use throttle and
brakes gradually, and shift weight uphill.
DISCRETIONARY WARNING (2–UP MODELS)
ALERT
Rear and understand your owner’s
manual.
Never operate this ATV on HILLS
steeper than 15 degrees. To prevent
overturn on hilly terrain, use throttle and
brakes gradually, and shift weight uphill.
31
SAFETY
TIRE PRESSURE/LOAD WARNING (1–UP MODELS)
ALERT
Improper tire pressure or overloading can cause loss of control. Loss of control
can result in severe injury or death. Always read and understand your owner’s
manual.
Cold tire pressure:
Front: 48,3 kPa (7.0 psi)
Rear: 48,3 kPa (7.0 psi)
TIRE PRESSURE/LOAD WARNING (2-UP MODELS)
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: 705 lbs. (320 kg)
Lug nut torque values:
Steel rims – 27 ft-lbs (37 Nm)
Aluminum rims – 30 ft-lbs (41 Nm) + 1/4 turn
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg).
NEVER exceed 50 MPH (80 kph) while carrying a passenger.
NEVER exceed 10 MPH (16 kph) when rear cargo loads are above 200 lbs (91
kg) and/or front cargo loads are 90 lbs (41 kg).
32
SAFETY
TIRE PRESSURE/LOAD WARNING (X2)
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: 705 lbs. (320 kg)
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
• NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs.
(91 kg) and/or front cargo loads are 90 lbs. (41 kg).
• Lug nut torque values:
Steel rims 27 ft-lbs. (37 Nm)
Aluminum rims 30 ft-lbs. (41 Nm) + 1/4 Turn
AGE 16 WARNING
WARNING
Operating this ATV if you are under the age of 16
increases the chances of severe injury or death to both
operator and passenger.
NEVER operate this vehicle if you are under age 16.
CLUTCH COVER WARNING
ALERT
• Moving parts hazard under beltclutch 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.
33
SAFETY
REVERSE OVERRIDE / AWD WARNING
ALERT
Read and understand your owner’s manual.
Improper use of override button can
lead to loss of control resulting in severe
injury or death. Do not activate override
while throttle is engaged. Always apply
throttle gradually, while in reverse.
Do not push switch to engage 4X4
(AWD) if the rear wheels are spinning.
This may cause severe drive shaft and
clutch damage.
REVERSE OVERRIDE WARNING (HD MODELS)
ALERT
Read and understand your owner’s manual.
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.
34
SAFETY
AWD WARNING (HD MODELS)
ALERT
Read and understand your owner’s manual.
Do not push switch to engage 4X4 (AWD) if the rear
wheels are spinning. This may cause severe drive
shaft and clutch damage.
RACK ALERT
ALERT
DO NOT TOW FROM RACK OR
BUMPER.
Tow only from tow hooks or hitch.
Maximum Rack Loads:
• FRONT – 41 kg
• REAR – 82 kg
RACK ALERT, FRONT (X2)
ALERT
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum combined Front Rack and Container Load: 90 lbs. (41 kg)
BOX WARNING (X2)
WARNING
Remove flammable material containers from box before filling.
WARNING
Passengers can be thrown off. This can cause serious injury or death. Never
carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
35
36
FEATURES AND CONTROLS
FEATURES AND CONTROLS
SWITCHES
q Ignition Switch
w Engine Stop Switch
r Headlight Switch
t 4x4 Switch
e Mode/Reverse Override Switch
IGNITION SWITCH/LIGHT SWITCH
Use the ignition switch to start the engine. The key can be removed from the
switch when it is in the OFF position.
OFF
Turn the key to the OFF position to stop the engine. Electrical circuits are off.
RUN
Turn the key the RUN position to activate electrical components. Electrical
circuits are on. Electrical equipment can be used.
START
Turn the key to the START position to engage the electric starter. See the
Starting the Engine section for starting procedures.
37
FEATURES AND CONTROLS
4X4 SWITCH (IF EQUIPPED)
The drive mode switch q controls the
All Wheel Drive (AWD/4X4) system.
Use this switch to engage AWD (4X4)
or 2X4. The vehicle automatically
engages 4X4 when operating in reverse
if the drive mode is set to AWD (4X4).
ENGINE STOP SWITCH
Move the stop switch w either left or
right to the OFF position to stop the
engine quickly.
Move the stop switch to the RUN
position before attempting to start the
engine. The engine will not start or run
when the switch is off. Both the main
switch and the engine stop switch will
shut off all electrical power to the
vehicle, including lights.
MODE/REVERSE OVERRIDE SWITCH
WARNING
Pressing the override button while the throttle is open can cause loss of
control, which may result in serious injury or death. Always release the throttle
before pressing the override button.
This vehicle is equipped with a reverse
speed limiter system. To gain additional
wheel speed while backing, release the
throttle and depress the override button
e. The reverse override button also
acts as a MODE button when held down
for approximately one half second. The
override button will not function as a
MODE button if the transmission is in
reverse.
38
FEATURES AND CONTROLS
HEADLIGHT SWITCH
Use the headlight switch to turn the
lights on and off and to change the
lights from high beam to low beam. The
key must be in the ON position and the
engine stop switch must be in the RUN
position.
AUXILIARY OUTLET
The vehicle is equipped with a 12-volt
accessory outlet on the dash. Use the
outlet to power an auxiliary light or other
optional accessories or lights. For
service, the dash outlet connection is
under the dash.
39
FEATURES AND CONTROLS
THROTTLE LEVER
WARNING
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Immediately contact your POLARIS dealer or
other qualified person for service if throttle problems arise.
Failure to check or maintain proper operation of the throttle system can result
in an accident if the throttle lever sticks during operation. Always check the
lever for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the electronic throttle control could result in failure to perform
as designed, which could result in an accident. Do not attempt to modify the
throttle control system or replace it with any after market throttle mechanisms.
Engine speed and vehicle movement
are controlled by pressing the throttle
lever q. The throttle lever is spring
loaded. Engine speed returns to idle
when the lever is released. This ATV is
equipped with a throttle release switch,
which is designed to reduce the risk of a
frozen or stuck throttle.
40
FEATURES AND CONTROLS
BRAKE LEVER
WARNING
Operating the ATV with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the ATV with a spongy-feeling
brake lever. Always contact your dealer for service before operating the
vehicle.
Squeeze the brake lever q toward the
handlebar to apply the front and rear
brakes. These brakes are hydraulically
activated disc type brakes that are
activated by only one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or
low master cylinder fluid level, which
must be corrected before riding.
Contact your POLARIS dealer or other
qualified service facility for proper
diagnosis and repairs.
41
FEATURES AND CONTROLS
MASTER CYLINDER/BRAKE FLUID
WARNING
An over-full master cylinder may cause brake drag or brake lock-up, which
could result in an accident. Maintain brake fluid at the recommended level. Do
not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake
fade and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master cylinder before each ride.
1. Position the ATV on a level surface.
2. Position the handlebars so the
master cylinder q is level.
3. View the brake fluid level through
the indicator window w on the top
of the master cylinder. The eye will
appear dark when the fluid level is
full. When fluid is low, the eye will
be clear.
4. If the fluid level is low, remove the
cover screws and add fluid to the
fill line. Do not overfill. Use DOT 4
brake fluid only.
5. Reinstall the cover. Torque screws
to 7 in-lbs (.8 Nm).
42
FEATURES AND CONTROLS
PARKING BRAKE
LOCKING THE PARKING BRAKE
WARNING
Operating the ATV while the parking brake is engaged could result in an
accident or fire. Always check to be sure the parking brake is disengaged
before operating.
1. Place the transmission in PARK.
2. Squeeze and release the brake
lever q two or three times, then
squeeze and hold.
3. Push the parking brake lock w
forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock,
squeeze and release the brake
lever. It will return to its unlocked
position.
The parking brake may relax if left on for a long period of time. Always block the
wheels to prevent rolling. Always block the wheels on the downhill side of the
ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill
position. Never depend on the parking brake alone if the ATV is parked on a hill.
Always block the wheels to prevent rolling.
43
FEATURES AND CONTROLS
AUXILIARY FOOT BRAKE
WARNING
Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the main
brake system. Should the main system fail, use the auxiliary foot brake q.
The auxiliary foot brake is located on the inside of the right footrest. Operate this
brake with your right foot. If the rear wheels slide while using the auxiliary brake,
reduce brake pedal pressure to brake the rear wheels without skidding.
BRAKE FLUID LEVEL
Check the brake fluid level frequently
for the auxiliary brake system. The
reservoir is located under the seat, near
the airbox.
Maintain the fluid level between the
maximum and minimum marks. Use
DOT 4 brake fluid only.
44
FEATURES AND CONTROLS
AUTOMATIC TRANSMISSION GEAR SELECTOR
The transmission gear selector w is located on the right side of the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
To shift gears, brake to a complete stop.
When the engine is idling, move the
lever to the desired gear.
NOTE
Shifting gears with the engine speed above idle or while the vehicle is moving
could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in PARK
and lock the parking brake.
TIP
To extend belt life, use low forward gear when pulling a heavy load at less than
seven miles per hour for extended periods and when operating uphill at a slow
speed.
45
FEATURES AND CONTROLS
FUEL CAP
This vehicle is equipped with a digital fuel gauge that will indicate a low fuel
condition. Refuel when the gauge indicates a low fuel condition.
Always refuel with the engine stopped,
and outdoors or in a well ventilated
area. Refuel on a level surface.
Remove the fuel tank cap to add fuel to
the fuel tank. Use either leaded or
unleaded gasoline with a minimum
pump octane number of 87 = (R + M/2)
octane. Do not use fuel with ethanol
content greater than 10 percent, such
as E-85 fuel.
PASSENGER SEAT BACKREST (TOURING)
The passenger backrest can be adjusted vertically.
1. Remove the five screws securing
the plastic seat cover. Lift the cover
upward to remove it from the
backrest frame.
2. To adjust the backrest upward or
downward, loosen the four vertical
adjustment bolts q on the back of
the backrest frame. Slide the
backrest upward or downward to the
desired position and tighten the
adjustment bolts.
3. Reinstall the backrest cover.
46
FEATURES AND CONTROLS
PASSENGER SEAT (X2)
Always make sure the passenger seat lock-out is functioning properly before
operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when operating
without a passenger. Always return the seat to the 1-up position for single-rider
operation.
Never carry cargo in the rear box when operating the ATV in the 2-up mode with
a passenger.
SEAT CONVERSION
To convert the back cargo rack to a passenger backrest, do the following:
1. Make sure the cargo box dump latch is securely latched.
2. Slide the seat latch levers inward to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
5. Lift the adjustment latch at the top of the passenger backrest. Raise the
backrest to the desired position. Release the latch, making sure it locks into
one of the three operating positions.
TIP
The backrest must be moved out of the lowest position before it can be
secured in the upright position. The lowest position is for seat storage only. Do
not leave the backrest in the lowest position. Always adjust the backrest to one
of the three operating positions.
6. Lower the operator backrest to create the passenger seat. Two retaining pins
under the seat should fit into the two grommets on the seat base.
7. Test the passenger seat lockout by attempting to release the cargo box dump
latch. If the dump latch releases, the seat is not secure. Repeat the set-up
procedure. If the lock-out is not working properly, do not allow a passenger to
ride the vehicle. See your POLARIS dealer for service.
8. To return the vehicle to single-rider operation, reverse all steps. Always lower
the passenger backrest to the lowest position before folding it down into the
cargo box. Slide the seat latch levers outward to secure the locks.
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.
47
FEATURES AND CONTROLS
EXTREME USE BATTERY
An optional extreme use battery may be available for your model. If the
performance of the factory-installed battery is inadequate due to operation in
extreme cold or due to extended use of multiple electrical accessories, your
POLARIS dealer can assist. Your dealer can provide any installation procedures
that may differ for an extreme use battery.
ALL WHEEL DRIVE SYSTEM
The All Wheel Drive system is controlled by the 4X4 switch.
4x4 Models
ADC Models
X2
ADC 4X4 MODE
When the switch is on ADC 4X4, the ADC system allows engine braking to all
four wheels when the vehicle descends a hill or incline. Always move the 4X4
switch to ADC 4X4 before ascending or descending a hill.
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.
48
FEATURES AND CONTROLS
TURF MODE (IF EQUIPPED)
When operating in TURF mode, the inside rear wheel will rotate independently
from the outside wheel during turns. Operate in TURF mode only as needed to
protect smooth, level surfaces from tire damage. DO NOT operate in TURF
mode when climbing or descending hills, when sidehilling, or when operating on
uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and
water crossings. Always operate in ADC 4X4 or 4X4 on these types of terrain.
WARNING
Operating in TURF mode when on sloped, uneven, or loose terrain could
cause loss of control and result in serious injury or death. One rear wheel may
slip and lose traction or may lift up and grab when it touches the ground again.
ENGAGING 4X4
The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the
vehicle's electronic system will not enable 4X4 until the engine RPM is below
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.
49
FEATURES AND CONTROLS
ALL WHEEL DRIVE SYSTEM
(UTILITY EDITION & UTE MODELS ONLY)
The All Wheel Drive system is
controlled by the AWD momentary
switch q.
Engage AWD before getting into
conditions where front wheel drive may
be needed. If the rear wheels are
spinning, release the throttle before
switching to AWD.
• Move the momentary switch to the right to engage AWD.
• Move the momentary switch to the right, past the AWD setting, to engage
ADC AWD (if equipped).
• Move the momentary switch to the far left to operate in two-wheel drive (2X4).
NOTICE
Switching to AWD or ADC AWD (if equipped) while the rear wheels are
spinning may cause severe drive shaft and gearcase damage. Always switch
to AWD or ADC AWD (if equipped) while the rear wheels have traction or are at
rest.
AWD MODE
Move the momentary switch to the right to engage AWD (4X4). AWD will engage
when engine speed slows to below 3100 RPM. The gauge will display “AWD”.
There is no limit to the length of time the vehicle may remain in AWD. The
vehicle automatically engages AWD when operating in reverse if the switch is
set to the AWD position.
Once enabled, AWD remains enabled until the switch is turned off. If the switch
is turned off while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.
When in AWD, the demand drive unit will automatically engage any time the rear
wheels lose traction. When the rear wheels regain traction, the demand drive
unit will automatically disengage.
2X4 MODE
Move the momentary switch to the far left to operate in two-wheel drive (2X4).
AWD will disengage when engine speed slows to below 3100 RPM. The gauge
will display “2X4.”
50
FEATURES AND CONTROLS
ADC AWD MODE (IF EQUIPPED)
Move the momentary switch to the right, past the AWD setting, to engage ADC
AWD (if equipped). When the switch is on ADC AWD, the ADC system allows
engine braking to all four wheels when the vehicle descends a hill or incline.
Always move the AWD switch to ADC AWD before ascending or descending a
hill.
ACTIVE DESCENT CONTROL (ADC) SYSTEM
The ADC system allows engine braking to all four wheels when the vehicle
descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill.
ENGAGING ACTIVE DESCENT CONTROL
The ADC system will automatically engage when all four of the following
conditions occur:
•
•
•
•
The 4X4 switch must be in the ADC 4X4 position
Vehicle speed must be 15 MPH (25 km/h) or less
The throttle must be closed (throttle lever released)
The transmission must be in gear (high, low or reverse)
DISENGAGING ACTIVE DESCENT CONTROL
The ADC system will automatically disengage if at least one of the following
conditions occur:
•
•
•
•
•
The 4X4 switch is moved out of the ADC 4X4 position
Vehicle speed exceeds 15 MPH (25 km/h)
The throttle is open (throttle is applied)
The transmission is shifted to neutral or park
X2 Model: The vehicle is on flat ground, or not actively descending a hill
51
FEATURES AND CONTROLS
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 Gear Indicator
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
– = Gear Signal Error (or shifter between gears)
w Display Area 2
This area displays odometer, trip meter, trip meter 2, voltage, engine
temperature, engine hour meter, programmable service hour interval,
ground speed, or engine RPM.
e Display Area 1
This area displays engine RPM, ground speed, or coolant temperature.
r Fuel Gauge
The segments of the fuel gauge show the level of fuel in the fuel tank.
When the last segment clears, a low fuel warning is activated. All
segments including the fuel icon will flash. Refuel immediately.
t Service Indicator
A flashing wrench symbol alerts the operator that the preset service
interval has been reached. Your POLARIS dealer can provide scheduled
maintenance. See page 62 for more information.
y Clock
The clock displays time in a 12-hour or 24-hour format.
u AWD Indicator
Segments of the indicator illuminate based on drive mode engaged.
52
FEATURES AND CONTROLS
INDICATOR LAMPS
q Check Engine
w EPS Warning (if
equipped)
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.
e Engine Hot
This lamp illuminates to indicate an overheated engine. If the
indicator flashes, a severe overheating condition exists.
r Neutral
This lamp illuminates when the transmission is in neutral and
the ignition key is in the ON position.
t Helmet/Seat Belt
This lamp flashes for several seconds when the key is turned
to the ON position. The lamp is a reminder to wear helmet and
seat belt (if equipped) before operating.
y High Beam
This lamp illuminates when the headlamp switch is set to high
beam.
u Chassis Fault
If applicable.
i Performance
On models equipped with a low speed limiter, indicator light
will remain on when low speed limiter is active.
Limited
53
FEATURES AND CONTROLS
DISPLAY AREA 1
Pressing the MODE button will change the information displayed in Area 1 q.
54
Speed
Engine
Temperature
RPM
Ambient
Temperature
(Optional)
FEATURES AND CONTROLS
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)
Trip 2
RPM
Voltage
Speed
Engine Hours
Service Hours
55
FEATURES AND CONTROLS
OPTIONS MENU
Press and hold the MODE button to enter the Options Menu.
OPTIONS MENU
NOTES
Diagnostic Codes
Only displays if fault codes are
present or stored
Units - Distance
Select MPH or KPH
Units - Temp
Select between °F and °C
Clock
Select between 12H or 24H, and set
time
Backlight Color
Select between Blue or Red
Backlight Level
Set backlight brightness level
Service Hours
View/Set Service hours
Exit Menu
Exit
56
FEATURES AND CONTROLS
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.
57
FEATURES AND CONTROLS
UNIT SELECTION TEMPERATURE
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Units - Temp” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q Press the MODE button.
w Toggle the Up/Down Buttons to change the units (°F or °C)
e With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
58
FEATURES AND CONTROLS
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.
59
FEATURES AND CONTROLS
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.
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.
60
FEATURES AND CONTROLS
BACK LIGHT LEVEL
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Backlight Level” from the Options Menu by pressing the MODE
button.
Reference the image shown above:
q Press the MODE button.
w Toggle the Up/Down Buttons to change the units (Increase or De­
crease Level)
e With the correct unit displayed, Press the mode button which will set
the unit and return to the Options Menu.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
61
FEATURES AND CONTROLS
SERVICE HOURS
1. Press and hold the MODE button to enter the Options Menu.
NOTICE
“OPTIONS” will display on the screen for 3 seconds before showing first menu
item.
2. Select “Service Hours” from the Options Menu by pressing the MODE button.
Reference the image shown above:
q Press the MODE button.
w Toggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100)
e With the correct unit displayed, press the MODE button, which will set
the unit and return you to the Options Menu.
NOTICE
To reset service hours after they have counted down to "0.0", reselect the
existing setpoint or select a new service hour value.
3. To exit the Options Menu the user can select Exit Menu function from
Options Menu, can hold Mode Button and exit out of Options Menu, or not
press any button for 10 seconds, which will exit out of the Options Menu.
62
FEATURES AND CONTROLS
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.
63
FEATURES AND CONTROLS
DIAGNOSTIC DISPLAY CODE DEFINITIONS
Open Load:There is a break in the wires that lead to the item listed in the chart
(injector, fuel pump, etc.), or the item has failed.
Short-to-Ground:The wire is shorted to ground between the electronic control
unit and the item listed in the chart.
Shorted Load:The wires leading to the item listed in the chart are shorted
together, or the item has shorted internally.
Short-to-Battery:The wire leading from the item listed in the chart to the
electronic control unit is shorted to a wire at battery voltage.
DIAGNOSTIC CODES
COMPONENT
Throttle Position
Sensor
Engine Temperature
Sensor
Intake Air
Temperature Sensor
Manifold Absolute
Pressure Sensor
Crankshaft Position
Sensor
Vehicle Speed Signal
Gear Sensor Signal
64
CONDITION
SPN
FMI
Voltage Too High
51
3
Voltage Too Low
51
4
Voltage Too High
110
3
Voltage Too Low
110
4
Temperature Too High
110
16
Engine Overheat
Shutdown
110
0
Voltage Too High
105
3
Voltage Too Low
105
4
Voltage Too High
102
3
Voltage Too Low
102
4
Signal Out of Range
102
2
Circuit Fault
636
8
Plausibility Fault
636
2
Speed Too High
84
8
Plausibility Fault
84
2
Voltage Too Low
523
4
Voltage Too Low
523
3
Signal Fault
523
2
FEATURES AND CONTROLS
DIAGNOSTIC CODES
COMPONENT
CONDITION
SPN
FMI
Injector 1 (MAG) (SDI
Part Load)
Driver Circuit Open/
Grounded
651
5
Driver Circuit Short to
B+
651
3
Driver Circuit
Grounded
651
4
Driver Circuit Open/
Grounded
652
5
Driver Circuit Short to
B+
652
3
Driver Circuit
Grounded
652
4
Ignition Coil Primary
Driver 1 (MAG)
Driver Circuit Short to
B+
1268
3
Ignition Coil Primary
Driver 2 (PTO)
Driver Circuit Short to
B+
1269
3
Fuel Pump Driver
Circuit
Driver Circuit Open/
Grounded
1347
5
Driver Circuit Short to
B+
1347
3
Driver Circuit
Grounded
1347
4
Driver Circuit Open/
Grounded
1071
5
Driver Circuit Short to
B+
1071
3
Driver Circuit
Grounded
1071
4
Driver Circuit Open/
Grounded
634
5
Driver Circuit Short to
B+
634
3
Driver Circuit
Grounded
634
4
Position Out of Range
634
7
Driver Circuit Open/
Grounded
1321
5
Injector 2 (PTO) (SDI
Part Load)
Fan Relay Driver
Circuit
Idle Air Control
Starter Enable Circuit
65
FEATURES AND CONTROLS
DIAGNOSTIC CODES
COMPONENT
Chassis Relay
All Wheel Drive
Control
System Power
Throttle Safety Signal
Active Descent
Control System
Idle Speed
66
CONDITION
SPN
FMI
Driver Circuit Short to
B+
1321
3
Driver Circuit
Grounded
1321
4
Driver Circuit Open/
Grounded
520208
5
Driver Circuit Short to
B+
520208
3
Driver Circuit
Grounded
520208
4
Driver Circuit Open/
Grounded
520207
5
Driver Circuit Short to
B+
520207
3
Driver Circuit
Grounded
520207
4
Voltage Too High
168
3
Voltage Too Low
168
4
Voltage Too High
520194
3
Voltage Too Low
520194
4
Signal Out of Range
520194
2
Throttle Stuck
520194
7
Driver Circuit Open/
Grounded
520203
5
Driver Circuit Short to
B+
520203
3
Driver Circuit
Grounded
520203
4
Speed Too High
520211
3
Speed Too Low
520211
4
FEATURES AND CONTROLS
DIAGNOSTIC CODES
COMPONENT
CONDITION
SPN
FMI
EPS MODELS ONLY
Vehicle Speed Sensor
Data Valid But Above
Normal Operational
Range - Most Severe
Level
84
0
Data Erratic,
Intermittent Or
Incorrect
84
2
Abnormal Rate Of
Change
84
10
Received Network
Data In Error
84
19
Data Valid But Above
Normal Operational
Range - Most Severe
Level
168
0
Voltage Above
Normal, Or Shorted To
High Source
168
3
Voltage Below
Normal, Or Shorted To
Low Source
168
4
Data Valid But Above
Normal Operational
Range - Most Severe
Level
190
0
Data Erratic,
Intermittent Or
Incorrect
190
2
Received Network
Data In Error
190
19
Bad Intelligent Device
Or Component
628
12
Out Of Calibration
628
13
Calibration
Out Of Calibration
630
13
Steering Over Current
Shut Down
Current Above Normal
Or Grounded Circuit
520221
6
Steering Excessive
Current Error
Current Above Normal
Or Grounded Circuit
520222
6
System Power
Engine Speed
ECU Memory
67
FEATURES AND CONTROLS
DIAGNOSTIC CODES
COMPONENT
CONDITION
SPN
FMI
EPS MODELS ONLY
Steering Torque
Partial Failure
Condition Exists
Steering Torque Full
Failure
Condition Exists
EPAS Inverter
Temperature
EPAS
Communications
Receive Data Error
Position Encoder
Error
EPAS Software Error
520223
31
520224
31
Data Valid But Above
Normal Operational
Range - Most Severe
Level
520225
0
Data Valid But Above
Normal Operating
Range - Moderately
Severe Level
520225
16
Data Erratic,
Intermittent Or
Incorrect
520226
2
Condition Exists
520226
31
Root Cause Not
Known
520228
11
Bad Intelligent Device
Or Component
520228
12
Condition Exists
520228
31
Bad Intelligent Device
Or Component
520229
12
Condition Exists
520229
31
520231
31
EPAS Power Save
Condition
Condition Exists
EPS SEPIC Voltage
Error
Voltage Above
Normal, Or Shorted To
High Source
524086
3
Voltage Below
Normal, Or Shorted To
Low Source
524086
4
68
OPERATION
OPERATION
WARNING
Failure to operate the vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Read and
understand all safety warnings outlined in the safety section of this owner’s
manual.
VEHICLE BREAK-IN PERIOD
The break-in period for your new POLARIS vehicle is the first 25 hours of
operation, or the time it takes to use the first two tanks full of gasoline. No single
action on your part is as important as a proper break-in period. Careful treatment
of a new engine and drive components will result in more efficient performance
and longer life for these components. Perform the following procedures
carefully.
NOTICE
Excessive heat build-up during the first three hours of operation will damage
close-fitted engine parts and drive components. Do not operate at full throttle
or high speeds during the first three hours of use.
Use of any improper oils may cause serious engine damage. POLARIS PS-4
Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle
engine.
69
OPERATION
ENGINE AND DRIVETRAIN BREAK-IN
1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always
exercise extreme caution whenever handling gasoline.
2. Check the oil level. See the Oil Check section for reference. Add the
recommended oil as needed to maintain the oil level in the safe operating
range.
3. Drive slowly at first. Select an open area that allows room to familiarize
yourself with vehicle operation and handling.
4. Avoid aggressive use of the brakes.
5. Vary throttle positions. Do not operate at sustained idle.
6. Pull only light loads.
7. Perform regular checks on fluid levels, controls and areas outlined on the
daily pre-ride inspection checklist.
8. During the break-in period, change both the oil and the filter at 25 hours or
one month.
9. Check fluid levels of transmission and all gearcases after the first 25 hours of
operation and every 100 hours thereafter.
BRAKE SYSTEM BREAK-IN
Apply only moderate braking force for the first 50 stops. Aggressive or overly
forceful braking when the brake system is new could damage brake pads and
rotors.
PVT BREAK-IN (CLUTCHES/BELT)
A proper break-in of the clutches and drive belt will ensure a longer life and
better performance. Break in the clutches and belt by operating at slower
speeds during the break-in period as recommended. Pull only light loads. Avoid
aggressive acceleration and high speed operation during the break-in period.
If a belt fails, always clean any debris from the PVT intake and outlet duct and
from the clutch and engine compartments when replacing the belt.
70
OPERATION
PRE-RIDE CHECKLIST
Failure to inspect and verify that the ATV is in safe operating condition before
operating increases the risk of an accident. Always inspect the ATV before each
use to make sure it's in safe operating condition.
ITEM
REMARKS
PAGE
Brake system/lever travel
Ensure proper operation
page 41
page 115
Brake fluid
Ensure proper level
page 44
Auxiliary brake
Ensure proper operation
page 44
Front suspension
Inspect, lubricate if necessary
-
Rear suspension
Inspect, lubricate if necessary
-
Steering
Ensure free operation
-
Tires
Inspect condition and pressure
Wheels/fasteners
Inspect, ensure fastener
tightness
-
Frame nuts, bolts, fasteners
Inspect, ensure tightness
-
Fuel and oil
Ensure proper levels
page 165
Coolant level
Ensure proper level
page 113
Coolant hoses
Inspect for leaks
-
Throttle
Ensure proper operation
page 40
Indicator lights/switches
Ensure operation
page 53
Engine stop switch
Ensure proper operation
page 38
Air filter, pre-filter
Inspect, clean
page 121
Headlamp
Check operation
page 37
Brake light/taillight
Check operation
-
Riding gear
Wear approved helmet,
goggles, and protective
clothing
page 11
Winch (if equipped)
Inspect cable and switch
page 91
page 117
71
OPERATION
SAFE OPERATION PRACTICES
1. Visit the Recreational Off-Highway Vehicle Association web site and take the
free on-line training course. Complete the recommended safety training
before operating this vehicle. Visit www.rohva.org or call 866-267-2751.
2. Do not allow anyone under 16 years of age or without a valid driver’s license
to operate this vehicle.
3. Never carry a passenger on this vehicle.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in
an enclosed area.
5. Never operate with accessories not approved by POLARIS for use on this
vehicle.
6. Operate this vehicle off-road only. Never operate this vehicle on any public
street, road or highway, including dirt and gravel roads (unless designated for
off-highway use).
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. Always operate at a speed that's appropriate for the terrain, the visibility and
operating conditions and your skills and experience. Never operate at
excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep
both hands on the steering wheel or handlebars during operation.
9. Never consume alcohol or drugs before or while operating this vehicle.
10. Always use the size and type of tires specified for your vehicle. Always
maintain proper tire pressure.
11. Never operate a damaged vehicle. After any rollover or accident, have a
qualified service dealer inspect the entire machine for possible damage.
12. 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.
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.
72
OPERATION
TRAIL ETIQUETTE
Always practice good etiquette when riding. Allow a safe distance between your
vehicle and other vehicles operating in the same area. Communicate to
oncoming operators by signaling the number of vehicles in your group. When
stopping, move your vehicle to the edge of the trail as far as possible to allow
others to pass safely.
KNOW YOUR RIDING AREA/TREAD LIGHTLY
Familiarize yourself with all laws and regulations concerning the operation of this
vehicle in your area. Respect the environment in which you ride your vehicle.
Find out where the designated riding areas are by contacting your POLARIS
dealer, a local riding club, or local officials.
Help keep our trails open for recreational vehicle use. As an off-road enthusiast,
you represent the sport and can set a good example (or a poor example) for
others to follow. Tread lightly. Operate with respect for the terrain, avoid littering,
and always stay on the designated trails.
STARTING THE ENGINE
1. Position the vehicle on a level surface outdoors or in a well- ventilated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
TIP
The starter interlock will prevent the engine from starting if the transmission is
in gear and the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
TIP
Do not press the throttle while starting the engine.
5. Turn the ignition key past the ON position to engage the starter. Activate the
starter for a maximum of five seconds, releasing the key when the engine
starts.
6. If the engine does not start, return the key to the OFF position and wait five
seconds before attempting to start again. Activate the starter for another five
seconds if necessary. Repeat this procedure until the engine starts.
NOTICE
Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.
73
OPERATION
COLD WEATHER OPERATION
If the vehicle is used year-round, check the oil level frequently. A rising oil level
could indicate the accumulation of contaminates such as water or excess fuel in
the bottom of the crankcase. Water in the bottom of the crankcase can lead to
engine damage and must be drained. Water accumulation increases as outside
temperature decreases.
NEW OPERATOR DRIVING PROCEDURES
1. Wear protective riding gear. See the Safe Riding Gear section.
2. Perform the pre-ride inspection.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and brakes on level
surfaces.
74
OPERATION
TURNING THE VEHICLE
Both rear wheels drive equally at all times. This means that the outside wheel
must travel a greater distance than the inside wheel when turning, and the inside
tire must slip traction slightly.
1. Slow down.
2. Never turn quickly when carrying cargo.
3. Steer in the direction of the turn.
4. Keep both feet on the footrests.
5. Lean your upper body to the inside of the turn while supporting your weight
on the outer footrest. This technique alters the balance of traction between
the rear wheels, allowing the turn to be made smoothly. The same leaning
technique should be used for turning in reverse.
6. Practice making turns at slow speeds before attempting to turn at faster
speeds
WARNING
Turning improperly can result in vehicle overturn. Never turn abruptly or at
sharp angles. Never turn at high speeds.
TURNING AROUND ON A HILL (K-TURN)
If the vehicle stalls while climbing a hill, never back it down the hill! Use the Kturn 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.
75
OPERATION
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.
76
OPERATION
DRIVING THROUGH WATER
Your ATV can operate through water with a maximum recommended depth
equal to the bottom of the footrests. Follow these procedures when operating
through water:
1. Determine water depths and current before entering water.
2. Choose a crossing where both banks have gradual inclines.
3. Avoid operating through deep or fast-flowing water.
NOTICE
Major engine damage can result if the vehicle is not thoroughly inspected
after operation in water. Perform the services outlined in the Periodic
Maintenance Chart. The following areas need special attention: engine oil,
transmission oil, demand drive fluid and all grease fittings.
If the vehicle tips or overturns in water, or if the engine stops during or after
operating in water, service is required before starting the engine. Your
POLARIS dealer can provide this service. If it's impossible to bring the vehicle
in before starting the engine, perform the service outlined in the Vehicle
Immersion section of this manual, and take the vehicle in for service at the
first opportunity.
77
OPERATION
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.
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.
78
OPERATION
DRIVING UPHILL
Braking and handling are greatly affected when operating in hilly terrain.
Improper procedure could cause loss of control or rollover. Whenever traveling
uphill, follow these precautions:
1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or
descending a hill. See page 47. Never operate in TURF mode while
operating on a hill or other irregular terrain.
2. Drive straight uphill.
3. Avoid steep hills. Maximum incline is:
• 15° (Touring/X2)
• 25° (1–Up Models)
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. A passenger should also 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.
Touring/X2
15°
1–Up Models
25°
79
OPERATION
DRIVING DOWNHILL
When driving downhill, follow these precautions:
1. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or
descending a hill. Never operate in TURF mode while operating on a hill or
other irregular terrain.
2. Avoid steep hills. Maximum incline is:
• 15° (Touring/X2)
• 25° (1-up Models)
3. Always check the terrain carefully before descending a hill.
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. A passenger should also 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.
Touring/X2
15°
80
1–Up Models
25°
OPERATION
DRIVING ON A SIDEHILL (SIDEHILLING)
Driving on a sidehill is not
recommended. Improper procedure
could cause loss of control or overturn.
Avoid crossing the side of any hill
unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Lean into the hill, transferring your upper body weight toward the hill while
keeping your feet on the footrests.
4. If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or
dismount on the uphill side immediately!
81
OPERATION
DRIVING IN REVERSE
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch unless additional wheel speed is required for
vehicle movement. Use the override with caution as rearward vehicle speed
is greatly increased. Do not operate at wide open throttle. Operate the
throttle just enough to maintain a desired speed.
NOTICE
Excessive throttle operation while in the speed limit mode may cause fuel to
build in the exhaust, resulting in engine popping and/or engine damage.
82
OPERATION
PARKING ON AN INCLINE
Avoid parking on an incline if possible. If it's unavoidable, follow these
precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
83
OPERATION
STOPPING THE ENGINE
1. Release the throttle pedal completely and brake to a complete stop.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
WARNING
A rolling vehicle can cause serious injury. Always place the transmission in
PARK when stopping the engine.
BRAKING
1. Release the throttle pedal completely. (When the throttle pedal is released
completely and engine speed slows to near idle, the vehicle has no engine
braking.)
2. Press on the brake pedal evenly and firmly. Practice starting and stopping
(using the brakes) until you're familiar with the controls.
PARKING THE VEHICLE
1. Stop the vehicle on a level surface. When parking inside a garage or other
structure, be sure that the structure is well ventilated and that the vehicle is
not close to any source of flame or sparks, including any appliance with pilot
lights.
2. Place the transmission in PARK.
3. Turn the engine off.
4. Engage the parking brake (if equipped).
5. Slowly release the brake pedal and make sure the transmission is in PARK
before exiting the vehicle.
6. Remove the ignition key to prevent unauthorized use.
84
OPERATION
HAULING CARGO
CARGO WARNING
WARNING
Overloading the vehicle or carrying or towing cargo improperly can alter
vehicle handling and may cause loss of control or brake instability, which can
result in serious injury or death. Always follow these precautions when hauling
cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, accessories, loads in the rack or box and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads
high on the racks raises the center of gravity of the vehicle and creates a less
stable operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the
vehicle.
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.
85
OPERATION
HAULING CARGO GUIDELINES
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. X2 Model: Always load a cargo box with the load as far forward as possible.
NEVER exceed 10 MPH (16 km/ h) when rear cargo loads are above 200
lbs. (91 kg) and/or front cargo loads are 90 lbs. (41 kg). Make sure the cargo
box dump latch is securely latched before loading and operating.
Unintentional dumping will result if weight is placed in the rear of the box and
the latch is not secured.
3. Models With Racks: Cargo weight should be evenly distributed with 1/3 on
the front rack and 2/3 on the rear rack and mounted as low as possible.
4. All Models: NEVER exceed 50 MPH (80 km/h) when rear cargo loads are
above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
2-Up Models: NEVER exceed 50 MPH (80 km/h) while carrying a
passenger.
5. When operating over rough or hilly terrain, reduce speed and cargo weight to
maintain stable driving conditions.
6. Do not obstruct the headlight beam with cargo.
7. Use low forward gear when hauling or towing heavy cargo.
8. Always operate the vehicle with extreme caution whenever hauling or towing
loads. Balance, handling and control may be affected.
TOWING LOADS
Always attach a towed load to the hitch point. Remove the hitch from the ATV
when not towing a trailer. If towing a load, reduce rear rack cargo weight by the
amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must not
exceed the rear rack capacity.
• The total load (operator, accessories, cargo and weight on hitch) must not
exceed the maximum weight capacity of the vehicle.
NOTICE
Using an improper hitch or exceeding the maximum tongue weight capacity
can result in serious damage to the vehicle and will void your ATV warranty.
Never install a hitch longer than 4" (10 cm). Never install automotive
accessories on your POLARIS ATV. Always install POLARIS-approved (or
equivalent) accessories designed for ATV use.
86
OPERATION
MAXIMUM TOWING CAPACITIES
Do not exceed maximum towing capacities. Avoid towing on inclines.
MODEL
CAPACITIES
FRONT HITCH
REAR HITCH
450 HO
450 HO EPS
570 570 EPS
570 Touring
570 Touring EPS
570 X2 EPS
Maximum Towed
Load
(Level Ground)
NA
1225 lbs
(555 kg)
Maximum Vertical
Hitch Weight
NA
120 lbs
(55 kg)
Maximum Towed
Load
(Level Ground)
NA
Maximum Vertical
Hitch Weight
NA
Maximum Towed
Load
(Level Ground)
850 lbs
(386 kg)
1225 lbs
(555 kg)
Maximum Vertical
Hitch Weight
85 lbs
(39 kg)
120 lbs
(55 kg)
Maximum Towed
Load
(Level Ground)
NA
1500 lbs
(680 kg)
Maximum Vertical
Hitch Weight
NA
150 lbs
(68 kg)
Maximum Towed
Load
(Level Ground)
NA
Maximum Vertical
Hitch Weight
NA
Maximum Towed
Load
(Level Ground)
NA
Maximum Vertical
Hitch Weight
NA
450 HD 2X4
450 Utility Edition
570 Utility Edition
570 SP
570 Touring SP
570 HD
570 UTE
87
OPERATION
CARGO BOX DUMPING (IF EQUIPPED)
NOTE
Sportsman® 6x6 570 shown for reference only.
1. Select a level site to dump the cargo box. Do not attempt to dump or unload
the vehicle while parked on an incline.
2. Place the transmission in PARK. Lock the parking brake.
3. Dismount the vehicle.
4. Lower the tailgate.
WARNING
If cargo weight is placed toward the rear of the cargo box, the load may dump
unexpectedly and cause serious injury. When loading cargo, always position
the weight as far forward and as low as possible.
5. Pull the cargo box release leverq upward.
6. Lift the front of the cargo box and dump the cargo.
88
OPERATION
7. Lower the cargo box and make sure the release latch is secured.
WARNING
To prevent a crushing injury to hands and fingers, keep hands and fingers
away from the lower front edge of the cargo box while lowering the box.
8. Secure the tailgate.
WARNING
Operating with the cargo box in the raised position can cause serious injury
and damage to the vehicle. The cargo box could close unexpectedly and injure
the driver. The rear tires will also catch the rear of the bed, damaging the
vehicle and creating hazardous driving conditions. Never operate this vehicle
with the cargo box in the raised position.
TOWING YOUR VEHICLE
If towing your vehicle is necessary, shift the transmission into neutral for better
mobility and to prevent damage to the belt. Always attach the tow cable to the
front tow loop of the disabled vehicle. A rider must be on board to steer the
disabled vehicle while towing.
TRAILERING YOUR VEHICLE
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Secure the fuel cap, oil cap, and seat.
4. Remove the key to prevent loss during transporting.
5. Always tie the frame of the vehicle to the transporting unit securely with
suitable straps or rope. Do not attach tie straps to the front A-arm bolt
pockets, racks, or handlebars.
89
90
WINCH GUIDE
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came equipped with
a winch or if you choose to add an accessory winch to your vehicle.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed
synthetic rope. The term “winch cable” will be used for either unless noted
otherwise.
WINCH SAFETY PRECAUTIONS
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the winch.
5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead
and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving vehicle.
See the Shock Loading section on page 99.
7. Always keep the area around the vehicle, winch, winch cable, and load clear
of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not
being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped
around the winch drum at all times. The friction provided by this wrapped
cable allows the drum to pull on the winch cable and move the load.
10. Always apply your vehicle’s park brake and/or park mechanism to hold the
vehicle in place during winching. Use wheel chocks if needed.
11. Always align the vehicle and winch with the load directly in front of the
vehicle as much as possible. Avoid winching with the winch cable at an angle
to the winching vehicle’s centerline whenever possible.
12. If winching at an angle is unavoidable, follow these precautions:
a. Look at the winch drum occasionally. Never let the winch cable “stack” or
accumulate at one end of the winch drum. Too much winch cable at one
end of the winch drum can damage the winch and the winch cable.
91
WINCH GUIDE
b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to
feed and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the winching
vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s rated
capacity.
15. The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the winch cable while winching a load.
17. Never let the winch cable run through your hands, even if wearing heavy
gloves.
18. Never release the clutch on the winch when the winch cable is under load.
19. Never use the winch for lifting or transporting people.
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Your dealer can provide
service on your winch if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage to winch
components.
24. Unplug the remote control from the vehicle when the winch is not in use to
prevent inadvertent activation and use by unauthorized persons.
25. Never grease or oil the winch cable. This will cause the winch cable to collect
debris that will shorten the life of the cable.
92
WINCH GUIDE
WINCH OPERATION
Read the Winch Safety Precautions in the preceding pages before using your
winch.
TIP
Consider practicing the operation and use of your winch before you actually
need to use it in the field.
WARNING
Improper winch use can result in SEVERE INJURY or DEATH. Always follow
all winch instructions and warnings in this manual.
Each winching situation is unique.
•
•
•
•
•
•
•
Take your time to think through the winching you are about to do.
Proceed slowly and deliberately.
Never hurry or rush during winching.
Always pay attention to your surroundings.
You may need to change your winching strategy if it is not working.
Always remember that your winch is very powerful.
There are simply some situations that you and your winch will not be able to
deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any
signs of damage or parts in need of repair or replacement before each use.
Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch
is being used (or has been used) for lifting an accessory plow assembly.
Promptly replace any worn or damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
3. Always apply your vehicle’s park brake and/ or park mechanism to hold the
vehicle in place during winching. Use wheel chocks if needed.
93
WINCH GUIDE
4. Always use the hook strap when handling the hook.
WARNING
Never put your fingers into the hook. This could lead to SEVERE INJURY.
• Attach the hook itself onto the load or use a tow strap or chain to secure
the load to the winch cable.
TIP
A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
WARNING
Never use a recovery strap when winching due to the excessive energy that
can be released if the winch cable breaks. This can result in SEVERE INJURY
or DEATH. See the Shock Loading section on page 99.
• Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
94
WINCH GUIDE
WARNING
Replace the winch cable at the first sign of damage to prevent SEVERE
INJURY or DEATH in the event of failure. For your safety, always replace
POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer, or other
qualified dealer.
• If possible, keep the winch cable aligned with the centerline of the
winching vehicle. This will help the spooling of the winch cable and reduce
the load on the fairlead.
• If freeing a stuck vehicle by attaching to a tree, use an item such as a tow
strap to avoid damaging the tree during winch operation. Sharp cables and
chains can damage and even kill trees. Please remember to
TreadLightly® (treadlightly.org).
• Before operating the winch, be sure that the safety latch on the winch
cable hook is fully seated when the load is attached.
• Never operate your winch with a damaged hook or latch. Always replace
damaged parts before using the winch.
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’s pulling
capacity. Always be sure that at least five (5) full turns of winch cable are
wrapped around the winch drum at all times. The friction provided by this
wrapped cable allows the drum to pull on the winch cable and move the load.
8. Read and adhere to the following information for winch damping to ensure
safe winch use.
a. In order to absorb energy that could be released by a winch cable failure,
always place a “damper” on the winch cable. A damper can be heavy
jacket, tarp, or other soft, dense object. A damper can absorb much of the
energy released if a winch cable breaks when winching. Even a tree limb
can help as a damper if no other items are available to you.
95
WINCH GUIDE
b. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
c. On a long pull, it may be necessary to stop winching so that the damper
can be repositioned to the new mid-point of the winch cable. Always
release the tension on the winch cable before repositioning the damper.
d. Avoid being directly in line with the winch cable whenever possible. Also,
never permit others to stand near or in line with the winch cable during
winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch
cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
11. The ONLY time a winch-equipped vehicle should be moving when using the
winch is when that vehicle itself is stuck. The winch equipped vehicle should
NEVER be in motion to “shock” load the winch cable in an attempt to move a
second stuck vehicle. See the Shock Loading section on page 99. For your
safety, always follow these guidelines when winching a vehicle free:
a. Release the winch clutch and spool out the necessary length of winch
cable.
b. Align the winch cable as close as possible to the winching vehicle’s
centerline.
c. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual.
d. Re-engage the clutch on the winch.
e. Slowly winch in the slack in the winch cable.
f. Select the proper vehicle gear to propel the stuck vehicle in the direction
of winching.
g. Shift to the lowest gear available on the stuck vehicle.
h. Slowly and carefully apply vehicle throttle and winch together to free the
vehicle.
i. Stop winching as soon as the stuck vehicle is able to propel itself without
the help of the winch.
j. Detach the winch cable hook.
k. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the winch cable to
a suspension component, brush guard, bumper or cargo rack. Vehicle
damage may result. Instead, attach the winch to a strong portion of the
vehicle frame or hitch.
96
WINCH GUIDE
13. Extensive winching will run down the battery on the winching vehicle. Let the
winching vehicle’s engine run while operating the winch to prevent the
battery from running low if winching for long periods.
14. The winch motor may become hot during winch use. If you winch for more
than 45 seconds, or if the winch stalls during operation, stop winching and
permit the winch to cool down for 10 minutes before using it again.
15. After winching is complete, especially if winching at an angle, it may be
necessary to re-distribute the winch cable across the winch drum. You will
need an assistant to perform this task.
a. Release the clutch on the winch.
b. Feed out the winch cable that is unevenly bunched up in one area.
c. Re-engage the winch clutch.
d. Have an assistant pull the winch cable tightly with about 100 lbs. (45 kg)
of tension using the hook strap.
e. Slowly winch the cable in while your assistant moves the end of the winch
cable back and forth horizontally to evenly distribute the winch cable on
the drum.
f. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
97
WINCH GUIDE
WINCH CABLE CARE
WARNING
Use of worn or damaged cable could lead to sudden failure and SEVERE
INJURY.
For your safety, always replace POLARIS winch parts (including the cable) with
genuine POLARIS replacement parts available at your authorized POLARIS
dealer, or other qualified person.
1. Always inspect your winch before each use. Inspect for worn or loose parts
including mounting hardware. Never use the winch if any part needs repair or
replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked
winch cable.
A kinked winch cable made of wire rope
is shown at right. Even after being
“straightened out,” this cable has
already been permanently and severely
damaged. Promptly discontinue use of
a winch cable in this condition.
A kinked winch cable made of wire rope
that has been “straightened out” is
shown at right. Even though it may look
usable, the cable has been permanently
and severely damaged. It can no longer
transmit the load that it could prior to
kinking. Promptly discontinue use of a
winch cable in this condition.
A winch cable made of synthetic rope
should be inspected for signs of fraying.
Replace the cable if fraying is observed
(shown below). Promptly discontinue
use of a winch cable in this condition.
Also replace the winch cable if there are
fused or melted fibers. Such an area of
the synthetic rope will be stiff and
appear smooth or glazed. Promptly
discontinue use of a winch cable in this
condition.
98
WINCH GUIDE
SHOCK LOADING
WARNING
Your winch cable is very strong but it is NOT designed for dynamic, or “shock”
loading. Shock loading may tension a winch cable beyond its strength and
cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope
and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up
slack in the winch cable by moving the winching vehicle in an attempt to
move an object. This is a dangerous practice. It generates high winch cable
loads that may exceed the strength of the cable. Even a slowly moving
vehicle can create large shock loads in a winch cable.
WARNING
SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”). This puts
extra load on the winch, winch cable, and generates excessive heat from the
motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an object with a
winch produces shock loading of the cable even when towing at slow
speeds. Towing from a winch also positions the towing force high on the
vehicle. This can cause instability of the vehicle and possibly lead to an
accident.
4. Never use recovery straps with your winch. Recovery straps are designed to
stretch and can store energy. This stored energy in the recovery strap is
released if a winch cable fails making the event even more hazardous.
Similarly, never use elastic “bungie” cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation
vehicle. This type of use also causes shock loading that can cause damage
to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced
by the winch motor when operated from a stationary vehicle. Always
remember that the winch and winch cable are NOT designed for shock
loading.
99
WINCH GUIDE
WINCH MAINTENANCE AND SERVICE SAFETY
WARNING
Improper or lack of winch maintenance and service could lead to SEVERE
INJURY or DEATH. Always follow all winch instructions and warnings in this
manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch
cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections
to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable)
with genuine POLARIS replacement parts available at your authorized
POLARIS dealer, or other qualified person.
5. Some winch models use wire rope as the winch cable. Other winches use a
specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer
rope such as can be purchased in a hardware store. Although they may look
similar, they are NOT alike. A polymer rope not designed for winch use will
stretch and store excessive energy when winching.
WARNING
Failure of a stretched rope under winching conditions will release all of the
stored energy. This will increase the chances of SEVERE INJURY or DEATH.
100
EMISSION CONTROL SYSTEMS
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.
101
102
MAINTENANCE
MAINTENANCE
PERIODIC MAINTENANCE
Any qualified repair shop or person may maintain, replace or repair the emission
control devices or systems on your vehicle. An authorized POLARIS dealer can
perform any service that may be necessary for your vehicle. POLARIS also
recommends POLARIS parts for emissions-related service, however equivalent
parts can be used.
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket
parts manufacturer reduces the effectiveness of the vehicle’s emission controls.
Tampering with emission controls is prohibited by federal law.
Owners are responsible for performing the scheduled maintenance identified in
this owner’s manual. Careful periodic maintenance will help keep your vehicle in
safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as
necessary. When inspection reveals the need for replacement parts, genuine
POLARIS parts are available from your POLARIS dealer. Equivalent parts may
be used for emissions-related service.
Record maintenance and service in the Maintenance Log beginning on page
179. Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, a qualified
dealer can perform these operations. Maintenance intervals in the following
chart are based upon average riding conditions and an average vehicle speed of
approximately 10 miles per hour. Vehicles subjected to severe use must be
inspected and serviced more frequently.
SEVERE USE DEFINITION
Severe use is defined as:
•
•
•
•
•
•
Frequent immersion in mud, water, or sand
Frequent or prolonged operation in dusty environments
Short trip cold weather operation
Racing or racing-style high RPM use
Prolonged low speed, heavy load operation
Extended idle
103
MAINTENANCE
MAINTENANCE CHART
SYMBOL
DESCRIPTION
XU
Perform these procedures more often for vehicles subjected to severe use.
D
Have an authorized Polaris dealer or other qualified person perform these services.
WARNING
Improperly performing the procedures marked with a D could result in
component failure and lead to serious injury or death. Have an authorized
POLARIS dealer or other qualified person perform these services.
Perform all services at whichever maintenance interval is reached first. Record
maintenance and service in the Maintenance Log.
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
HOURS
ITEM
CALENDAR
MILES
(KM) REMARKS
Steering
Front Suspension
Rear Suspension
Tires
Brake Fluid Level
Brake Lever Travel
Inspect and make adjustments as
needed.
Pre-Ride
Brake System
Wheels / Fasteners
CV Boot
Frame Fasteners
Engine Oil Level
Winch (if equipped)
XU
XU
D
104
Air Filter (PreFilter)
-
Daily
-
Inspect; clean often; replace as
needed
Coolant
-
Daily
-
Check level daily, change coolant
every two years
Head Lights / Tail
Lights
-
Daily
-
Check operation; apply dielectric
grease if replacing
Power Steering
unit
(If equipped)
-
Daily
Brake Pad Wear
10 H
Monthly
100
(160)
Inspect periodically
Battery
20 H
Monthly
200
(320)
Check terminals; clean; test
Inspect daily, clean often
MAINTENANCE
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
HOURS
ITEM
CALENDAR
MILES
(KM)
REMARKS
-
Inspect; cycle key to pressurize fuel
pump; check lines and fittings for
leaks and abrasion
1M
-
Break-in oil and filter change
25 H
1M
250
(400)
Break-in fluid level check
Rear Gearcase Oil
25 H
1M
250
(400)
Break-in fluid level check
Transmission Fluid
25 H
1M
250
(400)
Break-in fluid level check
Lubricate all fittings, pivots, cables,
etc.
Fuel System
20 H
Monthly
XU
Engine Oil Change
25 H
XU
Demand Drive
Fluid
XU
XU
General
Lubrication
50 H
3M
500
(800)
Shift Linkage
50 H
3M
500
(800)
Inspect
D
Steering
50 H
6M
500
(800)
Lubricate
XU
Front/Rear
Suspension
50 H
6M
500
(800)
Lubricate
XU
Throttle Release
Switch
50 H
6M
500
(800)
Inspect; adjust; lubricate; replace if
necessary
Throttle Body
Intake Duct
50 H
6M
500
(800)
Inspect ducts for proper sealing / air
leaks
Drive Belt
50 H
6M
500
(800)
Inspect; replace as needed
Air Filter (main
element)
50 H
6M
500
(800)
Inspect; replace as needed
Cooling System
50 H
6M
1000
(1600)
Inspect coolant strength seasonally;
pressure test system yearly
XU
Radiator
50 H
6M
1000
(1600)
Inspect; clean external surfaces
XU
Cooling Hoses
50 H
6M
1000
(1600)
Inspect for leaks
XU
Oil lines and
fasteners
100 H
6M
1000
(1600)
Inspect for leaks and loose fittings
XU
Engine oil change
100 H
6M
1000
(1600)
Change the oil and filter
XU
Demand drive fluid
(normal use)
100 H
12 M
1000
(1600)
Change fluid
XU
Rear gearcase oil
100 H
12 M
1000
(1600)
Change fluid
XU
Transmission oil
100 H
12 M
1000
(1600)
Change fluid
XU
XU
105
MAINTENANCE
MAINTENANCE INTERVAL
(WHICHEVER COMES FIRST)
HOURS
ITEM
CALENDAR
MILES
(KM)
Cycle key to pressurize fuel pump;
check for leaks at fill cap, fuel lines/
rail and fuel pump.
REMARKS
D
Fuel System
100 H
12 M
1000
(1600)
XU
Engine Mounts
100 H
12 M
1000
(1600)
Inspect
Exhaust Pipe /
Silencer
100 H
12 M
1000
(1600)
Inspect
XU
Spark Plug
100 H
12 M
1000
(1600)
Inspect; replace as needed
XU
Wiring
100 H
12 M
1000
(1600)
Inspect for wear, routing, security;
apply dielectric grease to connectors
subjected to water, mud, etc.
D
Clutches (Drive/
Driven)
100 H
12 M
1000
(1600)
Inspect; clean; replace worn parts
D
Wheel Bearings
100 H
12 M
1000
(1600)
Inspect; replace as needed
D
Brake Fluid
200 H
24 M
2000
(3200)
Change every two years
Spark Arrestor
300 H
36 M
3000
(4800)
Clean out; or remove clean out plug
-
60 M
-
Replace coolant (50/50 Extended
Life Coolant)
200 H
-
2000
(3200)
XU
Coolant
XU
Valve Clearance
D
Toe Adjustment
-
Inspect periodically; adjust as
needed
Headlight Aim
-
Adjust as needed
106
Inspect; adjust as needed
MAINTENANCE
LUBRICATION GUIDE
Check and lubricate all components at the intervals outlined in the Periodic
Maintenance Chart. Items not listed in the chart should be lubricated at the
General Lubrication interval.
The a-arms and lower control arms are lubricated at the factory, and no
additional lubrication will be needed. However, if these components are
subjected to severe use, grease zerks have been provided for additional
lubrication at the user's discretion.
ITEM
LUBE
CAPACITY AT FLUID
CHANGE
INSPECTION
PROCEDURE
Engine Oil (450/570)
PS-4 5W-50 4-Cycle
Oil
2 qt. (1.9 l)
Maintain level in safe
range on dipstick.
Brake Fluid
DOT 4 Brake Fluid
-
Maintain level
between fill lines.
Transmission Oil
AGL Gearcase
Lubricant &
Transmission Fluid
32 oz. (948 ml)
Maintain level at
bottom of fill hole
threads.
Demand Drive (Front
Gearcase)
Demand Drive
9 oz. (265 ml)
Maintain level at
bottom of fill hole
threads.
Front Prop Shaft
U-Joint Grease
-
Grease fittings (3
pumps maximum)
every 500 miles,
before long periods of
storage, or after
pressure washing or
submerging.
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.
107
MAINTENANCE
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
NOTE
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 right 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.
108
MAINTENANCE
OIL CHANGE
IMPORTANT
Always change the oil filter whenever changing oil.
See the fluid recommendation table for
capacities and plug torques. Always
change the oil at the intervals outlined in
the Periodic Maintenance Chart
beginning on page 104. 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.
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.
TORQUE
11 +/- 1 ft-lbs (16 +/- 1.5 Nm)
109
MAINTENANCE
OIL FILTER CHANGE
IMPORTANT
Always change the oil filter whenever changing oil.
See the fluid recommendation table for
capacities and plug torques. Always
change the filter at the intervals outlined
in the Periodic Maintenance Chart
beginning on page 104.
1. Place shop towels beneath the oil filter w. Using an oil filter wrench
(available from your POLARIS dealer), turn the filter counter- clockwise to
remove it.
2. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
3. 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.
4. 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.
5. Remove the dipstick.
6. Add the proper amount of the recommended oil. Do not overfill.
7. Reinstall the dipstick.
8. Place the transmission in PARK.
9. Lock the parking brake.
10. Start the engine. Allow it to idle for one to two minutes.
11. Stop the engine.
12. Check for leaks.
13. Check the oil level. Add oil as needed to bring the level to the upper mark on
the dipstick.
14. Dispose of used filter and oil properly.
110
MAINTENANCE
TRANSMISSION OIL
TORQUE
Fill Plug: 20–25 ft lbs. (27–34 Nm)
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 fill
plug is located on the right side of the ATV behind the footwell. The drain plug is
located on the bottom rear side of the gearcase.
OIL CHECK
1. Remove the fill plug q. 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
TORQUE
Drain Plug: 20–25 ft lbs. (27–34 Nm)
1. Place a drain pan under the
gearcase. Remove the drain plug w.
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.
111
MAINTENANCE
FRONT GEARCASE (DEMAND DRIVE) FLUID
Always check and change the demand drive fluid at the intervals outlined in the
Periodic Maintenance Chart.
Change the front gearcase fluid every 25 hours if the ADC unit is exposed to
extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
TIP
If the front gearcase is makes 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
TORQUE
Fill Plug: 8–10 ft lbs (11–14 Nm)
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.
112
MAINTENANCE
FLUID CHANGE
TORQUE
Drain Plug: 11 ft lbs (15 Nm)
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.
POWER STEERING UNIT
If your model is equipped with power steering, frequently clean the areas around
and on the power steering unit to allow proper cooling. Clean these areas
thoroughly.
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.
113
MAINTENANCE
RECOVERY BOTTLE COOLANT
The recovery bottle fluid level can be
accesses from the front left wheel well.
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.
114
MAINTENANCE
BRAKES
HAND BRAKE
The front and rear brakes are hydraulic disc brakes, activated by moving the
single brake lever toward the handlebar. These brakes are self- adjusting.
Under normal operation, the diaphragm extends into the reservoir as fluid level
drops. If the fluid level is low and the diaphragm is not extended, a leak is likely
and the diaphragm should be replaced. To ensure proper diaphragm operation,
always fill the reservoir as needed whenever the cover is loosened or removed.
Do not overfill.
WARNING
An over-full master cylinder may cause brake drag or brake lock- up, which
could result in serious injury or death. Maintain brake fluid at the recommended
level. Do not overfill.
The following checks are recommended to keep the brake system in good
operating condition. Check more often if brakes are used heavily under normal
operation.
1. Always keep brake fluid at an adequate level. See the Master Cylinder/Brake
Fluid section for details.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness. Replace brake
pads when they are worn to .030” (0.762 mm).
5. Check the security and surface condition of the disc. Clean any grease using
a recommended brake cleaner or alcohol. Do not use spray lubricants or
other petroleum-based products. If you discover any damage (cracks,
excessive corrosion, warping) see your dealer for service before operating.
AUXILIARY FOOT BRAKE
The hydraulic auxiliary brake system requires no adjustment. Check the brake
fluid level frequently for the auxiliary brake system.
115
MAINTENANCE
SEAT REMOVAL (TOURING/1–UP MODELS)
1. Locate the seat removal latch in the center of the seat’s rear.
2. Pull on the latch handle to disengage the seat from the vehicle’s frame.
3. Remove the seat.
SEAT REMOVAL (X2)
1. Remove any cargo from the cargo box before removing the seat.
2. Stand beside the vehicle. Pull the cargo box release lever upward. Lift the
front of the cargo box.
3. Grasp edge of the seat near the opposite rear corner.
4. Pull upward abruptly to disengage the under-seat fasteners.
5. Remove the seat.
SIDE PANEL REMOVAL
To remove the side panel, do the following:
1. Remove the seat.
2. Use a flat screwdriver to remove the plastic rivets securing the side panel.
3. Grasp the rear of the side panel near the rear cab. With a firm motion, pull
the side panel outward to disengage the side panel from the grommets.
4. Pull the panel outward and rearward to remove it.
FOOTWELL REMOVAL (1-UP MODELS)
To remove the footwell, do the following:
1. Remove the four screws on the bottom of the footwell.
2. Use a flat screwdriver to remove the plastic rivets securing the footwell to the
fenders.
3. Remove the footwell.
116
MAINTENANCE
FOOTWELL/FOOTWELL SUPPORT REMOVAL (2-UP
MODELS)
To remove the footwell, do the following:
1. Remove the six screws on the bottom of the footwell.
2. Use a flat screwdriver to remove the plastic rivets securing the footwell to the
fenders.
3. Remove the footwell.
4. If removing the footwell support is necessary to access the clutch cover,
remove the hex flange screw securing the support to the frame.
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 1/8” (3 mm) or less.
FRONT WHEEL HUB TIGHTENING
Front wheel bearing tightness and spindle nut retention are critical component
operations. All service must be performed by your authorized dealer or other
qualified service facility.
117
MAINTENANCE
WHEEL REMOVAL
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
WARNING
Do not service axle nuts that have a cotter pin installed. Your authorized dealer
can assist.
5. Elevate the side of the vehicle by placing a suitable stand under the foot rest
frame.
6. Remove the wheel nuts.
7. Remove the wheel.
WHEEL INSTALLATION
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside and
rotation arrows on the tire pointing toward forward rotation (if equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
WARNING
Loose nuts could cause a tire to come off during operation, which could result
in an accident or overturn. Always ensure that all nuts are torqued to
specification.
118
MAINTENANCE
WHEEL NUT TORQUE SPECIFICATIONS
Check the wheel nut torques occasionally and when they've been loosened for
maintenance service.
Lug Nut
(Aluminum
Wheels)
Front and Rear
30 ft. lbs. (41 Nm)
PLUS 1/4 TURN or
70 degrees
2-Piece Flange Nut
(Steel Wheels)
Front and Rear
27 ft. lbs. (37 Nm)
119
MAINTENANCE
TOE ALIGNMENT
WARNING
Severe injury or death can result from improper toe alignment and adjustment.
Do not attempt to adjust tie rod alignment. All tie rod adjustments should be
performed by an authorized POLARIS dealer or other qualified service facility.
Use the following procedure to check the toe alignment of the vehicle. The
recommended toe alignment is 1/4-1/2 inch (6-12 mm).
1. Position the vehicle on a level surface.
2. Place the handlebars in a straight-ahead position.
3. Tie a length of string between two stands. Position the stands so that the
string is flush with the side of the rear tire. If available, you may use a long
straight-edge instead of string.
4. Measure the distance from the string to the rim at the front q and rear w of
the front rim. The rear measurement should be 1/8–1/4 inch (3–6 mm) more
than the front measurement on each side of the vehicle to obtain the
recommended 1/4–1/2 inch (6–12 mm) toe out alignment.
5. Repeat the measurement procedure on the other side of the vehicle.
6. If you discover improper alignment, see your POLARIS dealer for service.
120
MAINTENANCE
AIR FILTER
1. Remove the seat. Remove the air
box cover clips. Remove the air box
cover q.
2. Remove the filter.
3. Remove the fabric type pre- filter
from the main filter. Wash the prefilter 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. Open the front box cover, and remove the access panel.
2. Remove 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.
4. Secure the fuse box cover and access panel.
5. Secure the front box cover.
121
MAINTENANCE
LIGHTS
CAUTION
Poor lighting can result in reduced visibility when driving. Headlight and taillight
lenses become dirty during normal operation. Clean headlights frequently and
replace burned out headlamps promptly.
Always make sure lights are adjusted properly for best visibility.
HEADLIGHT LAMP REPLACEMENT
When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from
your skin leaves a residue, causing a hot spot that will shorten the life of the
lamp. If fingers do touch a lamp, clean it with denatured alcohol.
CAUTION
Hot components can cause burns to skin. Allow lamps to cool before servicing.
1. Remove the seven (7) headlight pod screws. Pull the pod cover forward.
2. Unplug the headlamp from the wiring harness. Be sure to pull on the
connector, not on the wiring.
3. Turn the lamp counter-clockwise to remove it.
4. Apply dielectric grease to the socket and install the new lamp. Make sure the
tab on the lamp locates properly in the housing.
5. Reassemble the pod.
122
MAINTENANCE
HIGH BEAM ADJUSTMENT
The headlight beam can be adjusted slightly upward or downward. Use the
following procedure to make the adjustment.
NOTE
Image below is for reference only. Your model may differ slightly.
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 wallw. Include rider
weight on the seat when measuring.
5. The adjustment screw is located on the right side of the headlight pod. To
adjust the beam, loosen the screw. Adjust the headlamp to the desired
position, then tighten the screw.
123
MAINTENANCE
LOW BEAM ADJUSTMENT
The low beam can be adjusted slightly upward or downward.
1. Loosen the Phillips screw located at the rear of the headlamp.
2. Tilt the headlamp upward or downward.
3. Tighten the screw.
HEADLIGHT HOUSING REPLACEMENT
To replace the headlight housing, do the following:
1. Remove the seven (7) headlight pod
screws.
2. Pull the pod cover forward.
3. Unplug the headlamp from the
wiring harness.
4. Use a small screwdriver to remove
the o-rings from the headlight
mounting tabs.
5. Pull the headlight housing up from
bracket for removal.
6. Reverse the steps to install the new
housing and reassemble the pod.
LOWER HEADLAMP REPLACEMENT
1. Turn the back of the headlight harness counter-clockwise and pull the
harness assembly away from the headlight assembly.
2. Remove the headlamp and install the new headlamp.
3. Reinstall the harness assembly into the headlight assembly.
NOTE
Take care to avoid touching the glass on the new headlight bulb. Fingerprints
on the glass may result in premature failure.
4. Turn the headlight harness clockwise to secure the headlamp.
124
MAINTENANCE
TAILLIGHTS/BRAKE LIGHTS REPLACEMENT
Procedure to replace taillights:
ALL MODELS EXCEPT X2:
1. Remove the harness connector from the back of the light assembly.
2. Turn the lamp counter-clockwise to remove it.
3. Apply dielectric grease to the socket and install the new lamp.
4. Reinstall the harness connector.
5. Test the light for proper operation.
X2:
1. Open the tailgate.
2. Remove the two screws near the tailgate latch.
3. Grasp the entire taillight assembly and pull it away from the vehicle.
4. Remove the harness connector from the back of the light assembly.
5. Turn the lamp counter-clockwise to remove it.
6. Apply dielectric grease to the socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
125
MAINTENANCE
SPARK PLUGS
SPARK PLUG RECOMMENDATIONS
Refer to the specifications section for the recommended spark plug type and
gap for your vehicle. Torque spark plugs to specification.
NOTICE
Using non-recommended spark plugs can result in serious engine damage.
Always use POLARIS-recommended spark plugs or their equivalent.
ENGINE
TORQUE SPECIFICATION
450
15 ft-lbs (20 Nm)
570
9 ft-lbs (12 Nm)
SPARK PLUG INSPECTION
Spark plug condition is indicative of engine operation. Check the spark plug
firing end condition after the engine has been warmed up and the vehicle has
been driven at higher speeds. Immediately check the spark plug for correct
color.
CAUTION
A hot exhaust system and engine can cause burns. Wear protective gloves
when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Rotate the spark plug counter-clockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specification.
NORMAL PLUG
The normal insulator tip is gray, tan or light brown. There will be few combustion
deposits. The electrodes are not burned or eroded. This indicates the proper
type and heat range for the engine and the service.
The tip should not be white. A white insulator tip indicates overheating, caused
by use of an improper spark plug or incorrect throttle body adjustments.
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.
126
MAINTENANCE
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.
CAUTION
Serious damage could occur if the air box drain plug is not reinstalled 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.
CAUTION
Serious damage can occur after immersion if fluids are not changed promptly.
Your authorized dealer can assist.
7. Take the vehicle in for service as soon as possible, whether you succeed in
starting it or not. Your authorized dealer can provide the required service.
8. If water has been ingested into the PVT, follow the procedure in the PVT
System section for drying out the PVT.
127
MAINTENANCE
SPARK ARRESTER
WARNING
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 exhaust components.
To reduce fire hazard, make sure that there are no combustible materials in the
area when purging the spark arrestor.
Wear eye protection.
Do not stand behind or in front of the vehicle while purging the carbon from the
spark arrestor.
Never run the engine in an enclosed area.Exhaust contains poisonous carbon
monoxide gas.
Do not go under the machine while it is inclined.Set the hand brake and block
the wheels to prevent roll back.
Failure to heed these warnings could result in serious personal injury or death.
The exhaust pipe must be periodically purged of accumulated carbon as follows:
1. Remove the clean out plugs q located on the bottom of the muffler.
2. Place the transmission in Park and start the engine. Purge accumulated
carbon from the system by momentarily revving the engine several times.
3. If some carbon is expelled, cover the exhaust outlet w and lightly tap on the
pipe around the clean out plugs with a rubber mallet while revving the engine
several more times.
4. If particles are still suspected to be in the muffler, back the machine onto an
incline so the rear of the machine is one foot higher than the front. Set the
hand brake and block the wheels. Make sure the machine is in Park and
repeat Steps 2 and 3. SEE WARNING
128
MAINTENANCE
5. If particles are still suspected to be in the muffler, drive the machine onto the
incline so the front of the machine is one foot higher than the rear. Set the
hand brake and block the wheels. Make sure the machine is in Park and
repeat Steps 2 and 3. SEE WARNING
6. Repeat steps 2 through 5 until no more particles are expelled when the
engine is revved.
7. Stop the engine and allow the arrestor to cool.
8. Reinstall the clean out plugs.
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.
129
MAINTENANCE
For example, when operating at a ground speed of 3 MPH (5 km/h) in low range,
the engine speed would be around 3000 RPM. This is well above the
engagement speed of 1600 - 1800 RPM. However, in high range at 3 MPH (5
km/h), the engine would be running at only 1500 RPM. Whenever operating this
close to the engagement speed, the engine may be running at a speed too low
to provide the pinch needed to prevent belt slip. Belt slip is responsible for
creating the excessive heat that destroys belts, wears clutch components and
causes outer clutch covers to fail.
The air temperature in the clutch cover is substantially reduced by using low
range while operating at low ground speeds. Reducing the temperature inside
the clutch cover greatly extends the life of the PVT components (belt, cover,
etc.).
WHEN TO USE LOW RANGE AND HIGH RANGE
CONDITION
RANGE TO USE
Operating at speeds less than 7 MPH
(11 km/h)
Low
Towing heavy loads
Low
Operating in rough terrain (swamps,
mountains, etc.)
Low
Operating at speeds greater than 7
MPH (11 km/h)
High
PVT DRYING
There may be some instances when water is accidently ingested into the PVT
system. Use the following instructions to dry it out before operating.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall the
drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the
belt and clutches. Do not hold the throttle wide open for more than 5
seconds.
5. Allow the engine RPM to settle to idle speed, then shift the transmission to
low range.
6. Test for belt slippage. If the belt slips, repeat the process. Your vehicle
requires service as soon as possible, which your authorized dealer can
provide.
130
MAINTENANCE
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.
131
MAINTENANCE
BATTERY
WARNING
Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.
Your ATV is equipped with a sealed battery, which requires little maintenance.
POLARIS does not recommend using a conventional battery in this vehicle. The
orientation of the battery could result in electrolyte leakage, which would shorten
the life of the battery considerably.
Always keep battery terminals and connections free of corrosion. If cleaning is
necessary, remove corrosion with a stiff wire brush. Wash with a solution of one
tablespoon baking soda and one cup water. Rinse well with tap water and dry off
with clean shop towels. Coat the terminals with dielectric grease or petroleum
jelly.
BATTERY REMOVAL
NOTICE
If electrolyte spills, immediately wash it off with a solution of one tablespoon
baking soda and one cup water to prevent damage to the vehicle.
1. Disconnect the battery hold-down
strap.
2. Remove the battery cover (if
equipped).
3. On conventional batteries, remove
the battery vent tube.
4. Disconnect the black (negative)
battery cable first.
5. Disconnect the red (positive) battery
cable last.
6. Lift the battery out of the ATV. Be
careful not to tip a conventional
battery sideways, which could spill
electrolyte.
132
MAINTENANCE
BATTERY INSTALLATION
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. Follow the
battery charging procedure in Chapter 10 “Electrical” before installing the
battery.
CAUTION
To reduce the chance of sparks: Whenever removing the battery, disconnect
the black (negative) cable first. When reinstalling the battery, install the black
(negative) cable last.
NOTICE
Batteries on SP models are mounted outside the frame in a similar location. All
removal and installation steps are the same.
1. Clean battery cables and terminals with a stiff wire brush. Corrosion can be
removed using a solution of one cup water and one tablespoon baking soda.
Rinse well with clean water and dry thoroughly.
2. Place the Battery in the tray.
3. Coat terminals and bolt threads with Nyogel® Grease.
Nyogel® Grease
(PN 2871329)
4. Connect and tighten the red (positive) cable t. Torque to specification.
TORQUE
Battery Terminals:
5 ft-lbs (7 Nm)
133
MAINTENANCE
5. Connect and tighten the black (negative) cable r. Torque to specification.
TORQUE
Battery Terminals:
5 ft-lbs (7 Nm)
6. Install clear battery vent tube from vehicle to battery vent. (Applies to
Conventional Batteries Only).
WARNING
Vent tube must be free from obstructions and kinks and securely installed. If
not, battery gases could accumulate and cause an explosion. The vent tube
should be routed away from frame and body to prevent contact with Route the
cables correctly.
7. Install the battery cover e.
8. Install the battery strap w.
9. Verify that cables are properly routed.
134
MAINTENANCE
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 selfdischarge. Battery Tender can be left connected during the storage period, and
will automatically charge the battery if the voltage drops below a pre-determined
point. See the Polaris Products section for the part numbers.
BATTERY CHARGING
The following battery charging instructions apply only to the installation of a
sealed battery. Read all instructions before proceeding with the installation of
this battery.
The sealed battery is already filled with electrolyte and has been sealed and fully
charged at the factory. Never pry the sealing strip off or add any other fluid to this
battery.
The single most important thing about maintaining a sealed battery is to keep it
fully charged. Since the battery is sealed and the sealing strip cannot be
removed, you must use a voltmeter or multimeter to measure DC voltage.
WARNING
An overheated battery may explode, causing severe injury or death. Always
watch charging times carefully. Stop charging if the battery becomes very
warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. The battery should be disconnected from a load or charger for at least two
hours before checking voltage. Check the battery voltage with a voltmeter or
multimeter. A fully charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less
until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
following guidelines via the table below.
BATTERY CHARGING (SEALED BATTERY)
Always verify battery condition before and 1-2 hours after the end of charging.
135
MAINTENANCE
STATE OF CHARGE
VOLTAGE
ACTION
CHARGE TIME
(USING CONSTANT
CURRENT
CHARGER @
STANDARD AMPS
SPECIFIED ON TOP
OF BATTERY)
100%
12.8-13.0 volts
None, check at 3 mos.
from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no charge
given, check in 3
months
3-6 hours
50%-75%
12.0-12.5 volts
Needs charge
5-11 hours
25%-50%
11.5-12.0 volts
Needs charge
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less
Needs charge with
desulfating charger
At least 20 hours
CAMBER AND CASTER
The camber and caster are non-adjustable.
REAR SPRING
The rear shock absorber spring is adjusted by rotating the adjuster either
clockwise or counter-clockwise to increase or decrease spring tension.
Accessory springs are available through your POLARIS dealer.
HANDLEBARS
The handlebars can be adjusted for rider preference.
WARNING
Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the
handlebars, resulting in loss of control and serious injury or death. Follow the
adjustment procedures exactly, or see your POLARIS dealer for service.
1. Remove the 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.
136
MAINTENANCE
4. Torque the front two bolts to 10-12 ft-lbs (14-17 Nm), then torque the rear two
bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.
5. Re-intsall the headlight pod.
CLEANING AND STORAGE
WASHING THE VEHICLE
If a high pressure water system is used for cleaning (not recommended),
exercise extreme caution. The water may damage components and could
remove paint and decals. Avoid directing the water stream at the following items:
•
•
•
•
•
•
•
•
Wheel bearings
Radiator
Transmission seals
Cab and body panels
Electrical components
Switches and controls
Fuel system components
Labels and decals
If an informational or graphic label becomes illegible or comes off, contact your
POLARIS dealer to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge.
Grease all zerk fittings immediately after washing. Allow the engine to run for a
while to evaporate any water that may have entered the engine or exhaust
system.
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.
137
MAINTENANCE
POLISHING TIPS
• Avoid the use of automotive products, some of which can scratch the finish of
your vehicle.
• Always use clean cloths and pads for cleaning and polishing. Old or reused
cloths and pads may contain dirt particles that will scratch the finish.
STORAGE TIPS
NOTICE
Starting the engine during the storage period will disturb the protective film
created by fogging and damage could occur. Never start the engine during the
storage period.
CLEAN THE EXTERIOR
Make any necessary repairs and clean the vehicle as recommended. See the
Washing the Vehicle section.
STABILIZE THE FUEL
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or
equivalent fuel treatments or stabilizers. Follow the instructions on the
container for the recommended amount. Carbon Clean removes water from
fuel systems, stabilizes fuel and removes carbon deposits from pistons,
rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse
through the entire fuel delivery system.
OIL AND FILTER
Change the oil and filter. See the Engine Oil section.
AIR FILTER / AIR BOX
Replace the air filter. See Maintenance Chapter. Clean the air box.
FLUID LEVELS
Inspect the fluid levels. Add or change fluids as recommended in the Periodic
Maintenance Chart.
•
•
•
•
Demand drive fluid (front gearcase)
Rear gearcase fluid (if equipped)
Transmission fluid
Brake fluid (change every two years and any time the fluid looks dark or
contaminated)
• Coolant (test strength/fill)
138
MAINTENANCE
INSPECT AND LUBRICATE
Inspect all cables and lubricate all areas of the vehicle as recommended in the
Periodic Maintenance Chart.
FOG THE ENGINE
1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel
treatment. Follow the instructions on the container. Start the engine. Allow it
to idle for several minutes so the Carbon Clean reaches the injectors. Stop
the engine.
2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access
the plug holes, use a section of clear 1/4” hose and a small plastic squeeze
bottle filled with the pre-measured amount of oil. Do this carefully! If you miss
the plug holes, oil will drain from the spark plug cavities into the hole at the
front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification.
4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall
the cap onto the plug at this step.
5. Turn the engine over several times. Oil will be forced in and around the
piston rings and ring lands, coating the cylinder with a protective film of fresh
oil.
6. Reinstall the spark plug caps.
7. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and
injectors should be completely drained of gasoline.
BATTERY MAINTENANCE
See the Battery Storage and Battery Charging sections for storage and charging
procedures.
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.
139
MAINTENANCE
TRANSPORTING THE ATV
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Secure the fuel cap, oil cap and seats.
5. Always tie the frame of the ATV to the transporting unit securely with suitable
straps or rope. Do not attach tie straps to the front A- arm bolt pockets, racks
or handlebars.
6. Remove the key to prevent loss during transporting.
140
SPECIFICATIONS
SPECIFICATIONS
SPORTSMAN 450 HO / HO EPS
SPORTSMAN 450 HO / HO EPS
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
450 HO: 685 lbs. (311 kg)
450 HO EPS: 699 lbs. (317 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (54 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
Hitch Towing Rating
1225 lbs. (555.7 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
46 in. (117 cm)
Wheelbase
50.5 in. (128.3 cm)
Ground Clearance
10 in. (25.4 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Single overhead cam, 2 valve 4 stroke single
cyclinder
Displacement
500 cc
Bore x Stroke
93 mm x 73.6 mm
Alternator Output
660 W @ 7000 RPM
141
SPECIFICATIONS
SPORTSMAN 450 HO / HO EPS
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
5924 / 0.76-0.92 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, High
12.79:1
Drive Ratio, Front
3.818:1
Drive Ratio, Rear
3.7:1
Tires/Pressure, Front
24x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
24x10-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
142
SPECIFICATIONS
CLUTCHING
SHIFT WEIGHT
DRIVE CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
0-1800
(0-6000)
25–48
PN 5633217
Red/Blue
PN 7043372
Black
PN 7041782
1800-3700
(6000-12000)
28–36
PN 5633115
Blue/Red
PN 7043199
Black
PN 7041782
ALTITUDE
Meters (Feet)
SPORTSMAN 450 HD 2X4
SPORTSMAN 450 HD 2X4
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
640 lbs. (290 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (54 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
Hitch Towing Rating
1225 lbs. (555.7 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
46 in. (117 cm)
Wheelbase
50.5 in. (128.3 cm)
Ground Clearance
10 in. (25.4 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
143
SPECIFICATIONS
SPORTSMAN 450 HD 2X4
Engine
Single overhead cam, 2 valve 4 stroke single
cyclinder
Displacement
500 cc
Bore x Stroke
93 mm x 73.6 mm
Alternator Output
660 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
5924 / 0.76-0.92 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, High
12.79:1
Drive Ratio, Front
3.818:1
Drive Ratio, Rear
3.7:1
Tires/Pressure, Front
24x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
24x10-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
144
SPECIFICATIONS
SPORTSMAN 450 HD 2X4
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
CLUTCHING
SHIFT WEIGHT
DRIVE CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
0-1800
(0-6000)
25–48
PN 5633217
Red/Blue
PN 7043372
Black
PN 7041782
1800-3700
(6000-12000)
28–36
PN 5633115
Blue/Red
PN 7043199
Black
PN 7041782
ALTITUDE
Meters (Feet)
SPORTSMAN 450 UTILITY EDITION
SPORTSMAN 450 UTILITY EDITION
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
721 lbs. (327 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (54 kg) (Rear rack capacity and tongue
weight not to exceed 180 lbs./81.6 kg)
Hitch Towing Rating
1225 lbs. (555.7 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Front Hitch Maximum Towed Load (Level
Ground)
850 lbs. (386 kg)
145
SPECIFICATIONS
SPORTSMAN 450 UTILITY EDITION
Front Maximum Vertical Hitch Weight
85 lbs. (39 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
46 in. (117 cm)
Wheelbase
50.5 in. (128.3 cm)
Ground Clearance
10 in. (25.4 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Single overhead cam, 2 valve 4 stroke single
cyclinder
Displacement
500 cc
Bore x Stroke
93 mm x 73.6 mm
Alternator Output
660 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
5924 / 0.76-0.92 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, High
12.79:1
Drive Ratio, Front
3.818:1
Drive Ratio, Rear
3.7:1
146
SPECIFICATIONS
SPORTSMAN 450 UTILITY EDITION
Tires/Pressure, Front
24x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
24x10-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
CLUTCHING
SHIFT WEIGHT
DRIVE CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
0-1800
(0-6000)
25–48
PN 5633217
Red/Blue
PN 7043372
Black
PN 7041782
1800-3700
(6000-12000)
28–36
PN 5633115
Blue/Red
PN 7043199
Black
PN 7041782
ALTITUDE
Meters (Feet)
SPORTSMAN 570 / 570 EPS / 570 SP
SPORTSMAN 570 / 570 EPS / 570 SP
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
570: 677 lbs. (307 kg)
570 EPS: 690 lbs. (313 kg)
570 SP: 730 lbs. (331 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
147
SPECIFICATIONS
SPORTSMAN 570 / 570 EPS / 570 SP
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (55 kg)* (570/570 EPS)
150 lbs. (68 Kg)* (570 SP)
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
Hitch Towing Rating
1225 lbs. (557 kg) (570/570 EPS)
1500 lbs. (682 kg) (570 SP)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Front Hitch Maximum Towed Load (Level
Ground)
850 lbs. (386 kg)
Front Maximum Vertical Hitch Weight
85 lbs. (39 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
50.5 in. (128.3 cm)
Ground Clearance
11 in. (28 cm) (570/570 EPS)
12 in. (30.5 cm) (570 SP)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM (570/570 EPS)
660 W @ 7000 RPM (570 SP)
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
148
SPECIFICATIONS
SPORTSMAN 570 / 570 EPS / 570 SP
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel (570/
570 EPS)
Double A-Arm with 8.2" (21 cm) travel (570 SP)
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1 (570/570 EPS)
3.25:1 (570 SP)
Drive Ratio, Rear
3.7:1
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa) (570/570 EPS)
26x8-14 / 7 psi (48.3 kPa) (570 SP)
Tires/Pressure, Rear
25x10-12 / 7 psi (48.3 kPa) (570)
25x11-12 / 7 psi (48.3 kPa) (570 EPS/LE)
26x10-14 / 7 psi (48.3 kPa) (570 SP)
26x11-14 / 7 psi (48.3 kPa) (570 SP LE)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
149
SPECIFICATIONS
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
SPORTSMAN 570 HD
SPORTSMAN 570 HD
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
677 lbs. (307 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (55 kg)*
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
Hitch Towing Rating
1225 lbs. (557 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
50.5 in. (128.3 cm)
150
SPECIFICATIONS
SPORTSMAN 570 HD
Ground Clearance
11 in. (28 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
25x10-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
151
SPECIFICATIONS
SPORTSMAN 570 HD
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
SPORTSMAN 570 UTILITY EDITION
SPORTSMAN 570 UTILITY EDITION
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
755 lbs. (342 kg)
Fuel Capacity
4.5 gal. (17 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (55 kg)*
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
152
SPECIFICATIONS
SPORTSMAN 570 UTILITY EDITION
Hitch Towing Rating
1225 lbs. (557 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
83 in. (211 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
50.5 in. (128.3 cm)
Ground Clearance
11 in. (28 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
11.12:1
Drive Ratio, Front
3.82:1
153
SPECIFICATIONS
SPORTSMAN 570 UTILITY EDITION
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
25x10-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
SPORTSMAN TOURING 570 / 570 EPS / 570 SP
SPORTSMAN TOURING 570 / 570 EPS / 570 SP
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
570 Tour: 708 lbs. (321 kg)
570 Tour EPS: 722 lbs. (327 kg)
570 Tour SP: 759 lbs. (344 kg)
Fuel Capacity
6.25 gal. (23.7 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
154
SPECIFICATIONS
SPORTSMAN TOURING 570 / 570 EPS / 570 SP
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Receiver Hitch Tongue Capacity
120 lbs. (55 kg)* (570/570 EPS)
150 lbs. (68 Kg)* (570 SP)
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
Hitch Towing Rating
1225 lbs. (557 kg) (570/570 EPS)
1500 lbs. (682 kg) (570 SP)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Front Hitch Maximum Towed Load (Level
Ground)
850 lbs. (386 kg)
Front Maximum Vertical Hitch Weight
85 lbs. (39 kg)
Overall Length
86 in. (218.4 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
56 in. (142.2 cm)
Ground Clearance
11 in. (28 cm) (570/570 EPS)
12 in. (30.5 cm) (570 SP)
Minimum Turning Radius
82 in. (208.3 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM (570/570 EPS)
660 W @ 7000 RPM (570 SP)
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
155
SPECIFICATIONS
SPORTSMAN TOURING 570 / 570 EPS / 570 SP
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel (570/
570 EPS)
Double A-Arm with 8.2" (21 cm) travel (570 SP)
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1 (570/570 EPS)
3.25:1 (570 SP)
Drive Ratio, Rear
3.7:1
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa) (570/570 EPS)
26x8-14 / 7 psi (48.3 kPa) (570 SP)
Tires/Pressure, Rear
25x10-12 / 7 psi (48.3 kPa) (570)
25x11-12 / 7 psi (48.3 kPa) (570 EPS/LE)
26x10-14 / 7 psi (48.3 kPa) (570 SP)
26x11-14 / 7 psi (48.3 kPa) (570 SP LE)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
156
SPECIFICATIONS
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
18003700
(600012000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
SPORTSMAN X2 570 EPS
SPORTSMAN X2 570 EPS
Maximum Weight Capacity
485 lbs. (220 kg) (operator, cargo, accessories)
Dry Weight
767 lbs. (347.9 kg)
Fuel Capacity
6.25 gal. (23.7 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81.6 kg)
Hitch Tongue Weight
120 lbs. (55 kg)*
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
Hitch Towing Rating
1225 lbs. (557 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
89 in. (226 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
56 in. (142.2 cm)
157
SPECIFICATIONS
SPORTSMAN X2 570 EPS
Ground Clearance
11 in. (28 cm)
Minimum Turning Radius
65 in. (165 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
25x11-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
158
SPECIFICATIONS
SPORTSMAN X2 570 EPS
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
UTE 570
UTE 570
Maximum Weight Capacity
705 lbs. (320 kg) (operator, cargo, accessories)
Dry Weight
780 lbs. (354 kg)
Fuel Capacity
6.25 gal. (23.7 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
32 oz. (948 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack/Cargo Box Capacity
400 lbs. (181.4 kg)
Hitch Tongue Weight
120 lbs. (55 kg)*
*Rear rack capacity and tongue weight not to
exceed 180 lbs./81.6 kg
159
SPECIFICATIONS
UTE 570
Hitch Towing Rating
1225 lbs. (557 kg)
Unbraked Trailer Towing Capacity*
1786 lbs. (810 kg)
Overall Length
89 in. (226 cm)
Overall Width
48 in. (122 cm)
Overall Height
48 in. (122 cm)
Wheelbase
56 in. (142.2 cm)
Ground Clearance
11 in. (28 cm)
Minimum Turning Radius
82 in. (208.3 cm) unloaded
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
560 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1
160
SPECIFICATIONS
UTE 570
Tires/Pressure, Front
25x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
25x12.5-12 / 7 psi (48.3 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
SPORTSMAN® 6X6 570
SPORTSMAN® 6X6 570
Maximum Weight Capacity
1115 lbs. (505.8 kg) (includes operator,
passenger, cargo, accessories)
Dry Weight
1095 lbs. (496.7 kg)
Fuel Capacity
6.25 gal. (23.7 l)
Engine Oil Capacity
2 qts. (1.9 l)
Coolant Capacity
2.7 qts. (2.5 l)
Rear Gearcase Oil Capacity
7.1 oz. (210 ml)
161
SPECIFICATIONS
SPORTSMAN® 6X6 570
Demand Drive Fluid Capacity
9 oz. (265 ml)
Transmission Oil Capacity
33.8 oz. (1000 ml)
Front Rack/Storage Box Capacity
90 lbs. (40.8 kg)
Rear Rack Capacity
180 lbs. (81 kg)
Cargo Box Capacity
800 lbs. (362 kg)
Hitch Tongue Weight
150 lbs. (68 kg) (Rear box capacity and tongue
weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating
1500 lbs. (680 kg)
Unbraked Trailer Towing Capacity*
2127 lbs. (964 kg)
Overall Length
116 in. (294 cm)
Overall Width
49 in. (124 cm)
Overall Height
49 in. (124 cm)
Wheelbase
84 in. (213 cm)
Ground Clearance
11.5 in. (29 cm)
Minimum Turning Radius
160 in. (406 cm) (unloaded)
Rear Gearcase Oil Capacity
5 oz. (150 ml)
Engine
Dual overhead cam, 4 valve 4 stroke single
cylinder
Displacement
567 cc
Bore x Stroke
99mm x 73.6mm
Alternator Output
660 W @ 7000 RPM
Compression Ratio
10:1
Starting System
Electric
Ignition System
ECU
Idle RPM
1200 +/- 50
Spark Plug Type / Gap
NGK MR7F / 0.7-0.8 mm
Lubrication System
Wet Sump
162
SPECIFICATIONS
SPORTSMAN® 6X6 570
Driving System Type
Automatic PVT (POLARIS Variable
Transmission)
Front Suspension
MacPherson strut with 8.2" (21 cm) travel
Rear Suspension
Linear rate with 9.5" (24 cm) travel
Transmission
H/L/N/R/P
Gear Reduction, Low
23.91:1
Gear Reduction, Reverse
21.74:1
Gear Reduction, Forward
9.75:1
Drive Ratio, Front
3.82:1
Tires/Pressure, Front
26x8-12 / 7 psi (48.3 kPa)
Tires/Pressure, Rear
26x11-12 / 10 psi (68.9 kPa)
Brakes, Front/Rear
Single-Control Hydraulic Disc
Brakes, Auxiliary
Foot-Activated Hydraulic Disc
Brake, Parking
Hydraulic lock, all wheel
Headlight
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
Taillights
8.26 watts
Brake Light
26.9 watts
Instrument Cluster
LCD
* Based on EU Directive 76/432/EC
CLUTCHING
SHIFT
WEIGHT
DRIVE
CLUTCH
SPRING
DRIVEN
CLUTCH
SPRING
HELIX*
0-1800
(0-6000)
25-52G
PN 5632409
Black
PN 7043594
EBS Black
PN 7044505
EBS
PN 3235784
1800-3700
(6000-12000)
25-48
PN 5633217
Black
PN 7043594
Non-EBS
Red
PN 3234451
Non-EBS
PN 5132344
ALTITUDE
Meters (Feet)
*EBS models require no helix/spring adjustment
163
164
POLARIS PRODUCTS
POLARIS PRODUCTS
LUBRICANTS / SERVICE PRODUCTS
PRODUCT
SIZE (QUANTITY)
PART NUMBER
12 oz aerosol (12)
2870791
1 qt (12)
2871517
1 qt (12)
2876244
2 qt (8)
2877490
Fogging Oil
PS-4
PS-4 Extreme Duty
1 gal (4)
2876245
1 qt (12)
2878920
2 qt (8)
2878922
1 gal (4)
2878919
1 qt (12)
2878068
1 gal (4)
2878069
AGL
Pump for Gallon Jug
3.8 l
2870465
1 qt (12)
2877922
2.5 gal (2)
2877923
1 qt (12)
2880514
1 gal (6)
2880513
—
2871312
Four 3 oz packs (6)
2871322
14 oz cartridge
2871423
—
2871460
Demand Drive
Antifreeze / Coolant
Grease Gun Kit, Premium All
Season
All Season Grease
Premium Starter Grease
3 oz tube (24)
2871515
14 oz cartridge
2871551
Dielectric Grease (Nyogel™)
—
2871329
Carbon Clean
12 oz bottle (12)
2871326
16 oz (12)
2870652
2.5 gal (2)
2872280
U-Joint Grease
Fuel Stabilizer
DOT 4 Brake Fluid
—
2872189
Loctite™ 565 Thread Sealant
—
2871956
POLARIS Battery Tender™
Charger
—
2859044
165
166
TROUBLESHOOTING
TROUBLESHOOTING
DRIVE BELT WEAR/BURN
POSSIBLE CAUSE
SOLUTION
Driving onto a pickup or tall
trailer in high range
Use low range during loading.
Starting out going up a steep
incline
Use low range.
Driving at low RPM or ground
speed (3-7 MPH)
Drive at a higher speed or use low range more frequently.
Insufficient warm-up at low
ambient temperatures
Warm the engine at least 5 minutes. With the transmission in
neutral, advance the throttle to about 1/8 throttle in short bursts, 5
to 7 times. The belt will become more flexible and prevent belt
burning.
Slow/easy clutch engagement
Use the throttle quickly and effectively.
Towing/pushing at low RPM/
low ground speed
Use low range only.
Utility use/plowing
Use low range only.
Shift the transmission to low range and carefully use fast,
aggressive throttle application to engage clutch.
Stuck in mud or snow
WARNING: Excessive throttle may cause loss of control and
vehicle rollover.
Climbing over large objects
from a stopped position
Shift the transmission to low range and carefully use fast, brief,
aggressive throttle application to engage clutch.
WARNING: Excessive throttle may cause loss of control and
vehicle rollover.
Belt slippage from water or
snow ingestion into the PVT
system
Dry out the PVT. Prevent water from entering the PVT intake duct.
See Intake Pre-Filters for more information. Inspect clutch seals
for damage if repeated leaking occurs.
Clutch malfunction
Your dealer can assist.
Poor engine performance
Check for fouled plug or foreign material in gas tank or fuel lines.
Your POLARIS dealer can assist.
Slippage from failure to warm
up belt
Always warm up the belt by operating below 30 mph for one mile
(5 miles or more when temperature is below freezing).
Wrong or missing belt
Install the recommended belt.
Improper break-in
Always break in a new belt and/or clutch.
167
TROUBLESHOOTING
ENGINE DOESN'T TURN OVER
POSSIBLE CAUSE
SOLUTION
Low battery voltage
Recharge the battery to 12.8 VDC
Loose battery connections
Check all connections and tighten
Loose solenoid connections
Check all connections and tighten
Loose electronic control box
connections
Inspect, clean, reinstall connectors
ENGINE TURNS OVER, FAILS TO START
POSSIBLE CAUSE
SOLUTION
Out of fuel
Refuel
Water is present in fuel
Drain the fuel system and refuel
Old or nonrecommended fuel
Replace with fresh recommended fuel
Fouled or defective
spark plug
Inspect plug and replace if necessary
No spark to spark plug
Inspect plug and replace if necessary
Water or fuel in
crankcase
Your authorized dealer can assist
Low battery voltage
Recharge the battery to 12.8 VDC
Mechanical failure
Your authorized dealer can assist
ENGINE BACKFIRES
POSSIBLE CAUSE
SOLUTION
Weak spark from spark
plug
Inspect, clean and/or replace spark plug
Incorrect spark plug gap
or heat range
Set gap to specs or replace plug
Old or nonrecommended fuel
Replace with fresh recommended fuel
Incorrectly installed
spark plug wires
Your authorized dealer can assist
168
TROUBLESHOOTING
POSSIBLE CAUSE
SOLUTION
Mechanical failure
Your authorized dealer can assist
Loose ignition
connections
Check all connections and tighten
Water present in fuel
Replace with fresh recommended fuel
ENGINE PINGS OR KNOCKS
POSSIBLE CAUSE
SOLUTION
Poor quality or low octane fuel
Replace with recommended fuel
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES
POSSIBLE CAUSE
SOLUTION
Fouled or defective spark plug
Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your authorized dealer can assist
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
Loose ignition connections
Check all connections and tighten
Water present in fuel
Replace with new fuel
Low battery voltage
Recharge battery to 12.8 VDC
Incorrect fuel
Replace with recommended fuel
Clogged air filter
Inspect and clean or replace
Clogged intake pre-filter
Inspect and clean (with soapy water) or replace
Other mechanical failure
Your authorized dealer can assist
169
TROUBLESHOOTING
ENGINE STOPS OR LOSES POWER
POSSIBLE CAUSE
SOLUTION
Out of fuel
Refuel
Kinked or plugged fuel vent
line
Inspect and replace
Water is present in fuel
Replace with new fuel
Fouled or defective spark plug
Inspect, clean and/or replace spark plug
Worn or defective spark plug
wires
Your authorized dealer can assist
Incorrect spark plug gap or
heat range
Set gap to specs or replace plug
Loose ignition connections
Check all connections and tighten
Low battery voltage
Recharge the battery to 12.8 VDC
Incorrect fuel
Replace with fresh recommended fuel
Clogged air filter
Inspect and clean or replace
Clogged intake pre-filter
Inspect and clean (with soapy water) or replace
Other mechanical failure
Your authorized dealer can assist
Overheated engine
Clean radiator screen and core, clean engine exterior. Your
dealer can assist.
170
WARRANTY
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.
171
WARRANTY
WARRANTY COVERAGE AND EXCLUSIONS
LIMITATIONS OF WARRANTIES AND REMEDIES
This POLARIS limited warranty excludes any failures that are not caused by a
defect in material or workmanship. THIS WARRANTY DOES NOT COVER
CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of
God, accidental damage, normal wear and tear, abuse or improper handling.
This warranty also does not cover any vehicle, component, or part that has been
altered structurally, modified, neglected, improperly maintained or used for
racing, competition or purposes other than for which it was designed.
This warranty excludes damages or failures resulting from improper lubrication;
improper engine timing; improper fuel; surface imperfections caused by external
stress, heat, cold or contamination; operator error or abuse; improper
component alignment, tension, adjustment or altitude compensation; snow,
water, dirt or other foreign substance ingestion/contamination; improper
maintenance; modified components; use of aftermarket or unapproved
components, accessories, or attachments; use of unapproved software or
calibration; unauthorized repairs; or repairs made after the warranty period
expires or by an unauthorized repair center.
This warranty excludes damages or failures caused by abuse, accident, fire, or
any other cause other than a defect in materials or workmanship and provides
no coverage for consumable components, general wear items, or any parts
exposed to friction surfaces, stresses, environmental conditions and/or
contamination for which they were not designed or not intended, including but
not limited to the following items:
•
•
•
•
•
•
•
•
•
•
•
Wheels and tires
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Light bulbs/Sealed beam lamps
Filters
Lubricants
Bushings
172
• 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
WARRANTY
LUBRICANTS AND FLUIDS
1. Mixing oil brands or using non-recommended oil may cause engine damage.
We recommend the use of POLARIS engine oil.
2. Damage or failure resulting from the use of non-recommended lubricants or
fluids is not covered by this warranty.
This warranty provides no coverage for personal loss or expense, including
mileage, transportation costs, hotels, meals, shipping or handling fees, product
pick-up or delivery, replacement rentals, loss of product use, loss of profits, or
loss of vacation or personal time.
THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE,
AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE
MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH
IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY
PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO
LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR
SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF
CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS
INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE
EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.
THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS
EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED
WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED
WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE
ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL
EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES
DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION
OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY
TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
173
WARRANTY
HOW TO OBTAIN WARRANTY SERVICE
If your vehicle requires warranty service, you must take it to a POLARIS
Servicing Dealer. When requesting warranty service you must present your copy
of the Warranty Registration Form to the dealer. (THE COST OF
TRANSPORTATION TO AND FROM THE DEALER IS YOUR
RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer;
however, you may use any POLARIS Servicing Dealer to perform warranty
service.
IN THE COUNTRY WHERE YOUR PRODUCT WAS
PURCHASED:
Warranty or Service Bulletin repairs must be done by an authorized POLARIS
dealer, or other qualified person. If you move or are traveling within the country
where your product was purchased, Warranty and Service Bulletin repairs may
be requested from any authorized POLARIS dealer, or other qualified person,
that sells the same line as your product.
OUTSIDE THE COUNTRY WHERE YOUR PRODUCT WAS
PURCHASED:
If you are traveling temporarily outside the country where your product was
purchased, you should take your product to an authorized POLARIS dealer, or
other qualified person. You must show the dealer photo identification from the
country of the selling dealer's authorized location as proof of residence. Upon
residence verification, the servicing dealer will be authorized to perform the
warranty repair.
IF YOU MOVE:
If you move to another country, be sure to contact POLARIS Customer
Assistance and the customs department of the destination country before you
move. Product importation rules vary considerably from country to country. You
may be required to present documentation of your move to POLARIS in order to
continue your warranty coverage. You may also be required to obtain
documentation from POLARIS in order to register your product in your new
country. You should warranty register your product at a local POLARIS dealer in
your new country immediately after you move to continue your warranty
coverage and to ensure that you receive information and notices regarding your
vehicle.
IF YOU PURCHASE FROM A PRIVATE PARTY:
If you purchase a POLARIS product from a private party, to be kept and used
outside of the country in which the product was originally purchased, all warranty
coverage will be denied. You must nonetheless register your product under your
name and address with a local POLARIS dealer in your country to ensure that
you receive safety information and notices regarding your product.
174
WARRANTY
EXPORTED PRODUCTS
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT
IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S
AUTHORIZED LOCATION. This policy does not apply to products that have
received authorization for export from POLARIS. Dealers may not give
authorization for export. You should consult an authorized dealer to determine
this product's warranty or service coverage if you have any questions. This
policy does not apply to products registered to government officials or military
personnel on assignment outside the country of the selling dealer's authorized
location. This policy does not apply to Safety Bulletins.
NOTICE
If your product is registered outside of the country where it was purchased and
you have not followed the procedure set above, your product will no longer be
eligible for warranty or service bulletin coverage of any kind, other than safety
bulletins. Products registered to government officials or military personnel on
assignment outside of the country where the product was purchased will
continue to be covered by the Limited Warranty.
Please work with your dealer to resolve any warranty issues. Should your dealer
require any additional assistance, they will contact the appropriate person at
POLARIS.
This warranty gives you specific legal rights, and you may also have other rights
which vary from state to state or in different countries. If any of the above terms
are void because of federal, state, local law, all other warranty terms will remain
in effect.
For questions call POLARIS Customer Assistance:
United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334
175
WARRANTY
U.S.A. EPA EMISSIONS LIMITED WARRANTY
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is
first purchased, this emissions-certified vehicle is designed, built and equipped
so it conforms with applicable U.S. Environmental Protection Agency emission
regulations. POLARIS warrants that the vehicle is free from defects in materials
and workmanship that would cause it to fail to meet these regulations.
The warranty period for off road vehicles 100cc or greater emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues
for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever
comes first. The warranty period for ATVs less than 100cc emissions-certified
vehicles starts on the date of purchase by original retail purchaser and continues
for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever
comes first. This EPA emissions warranty period is extended for at least as long
as the standard factory warranty that Polaris provides on the vehicle as a whole.
The EPA emissions warranty period does not further extend if you purchase
additional warranty coverage in the form of a service contract or other paid
warranty extension, but emission-related parts may be covered subject to the
terms of any such paid service contract or paid warranty extension.
This emissions limited warranty covers components whose failure increases the
vehicle's regulated emissions, and it covers components of systems whose only
purpose is to control emissions. Repairing or replacing other components not
covered by this warranty is the responsibility of the vehicle owner. This
emissions limited warranty does not cover components whose failure does not
increase the vehicle's regulated emissions.
For exhaust emissions, emission-related components include any engine parts
related to the following systems:
• Air-induction system
• Fuel system
• Ignition system
• Exhaust gas recirculation systems
The following parts are also considered emission-related components for
exhaust emissions:
• Aftertreatment devices
• Crankcase ventilation valves
176
• Sensors
• Electronic control units
WARRANTY
The following parts are considered emission-related components for evaporative
emissions:
•
•
•
•
•
•
•
•
•
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is
to reduce emissions or whose failure will increase emissions without significantly
degrading engine/equipment performance. The exclusive remedy for breach of
this limited warranty shall be, at the exclusive option of POLARIS, repair or
replacement of any defective materials, components or products. THE
REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT
OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL,
AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE
ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may
not apply if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship. This limited warranty does not cover damage due to accidents,
abuse or improper handling, maintenance or use. This limited warranty also
does not cover any engine that has been structurally altered, or when the vehicle
has been used in racing competition. This limited warranty also does not cover
physical damage, corrosion or defects caused by fire, explosions or other similar
causes beyond the control of POLARIS.
177
WARRANTY
Owners are responsible for performing the scheduled maintenance identified in
the owner's manual. POLARIS may deny warranty claims for failures that have
been caused by the owner's or operator's improper maintenance or use, by
accidents for which POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the
emission control devices or systems on your vehicle. An authorized POLARIS
dealer, or other qualified person, can perform any service that may be necessary
for your vehicle. POLARIS also recommends POLARIS parts, however
equivalent parts may be used for such service. It is a potential violation of the
Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the
effectiveness of the vehicle's emission controls. Tampering with emission
controls is prohibited by federal law.
CALIFORNIA RESIDENTS
Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state
versions. Only the 50-state models are certified for sale in California. The 50state 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
178
MAINTENANCE LOG
MAINTENANCE LOG
MAINTENANCE LOG
Use the following chart to record periodic maintenance.
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED /
COMMENTS
179
180
2X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
2X4 Mode (Utility Edition and
UTE Models). . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4X4 (AWD) Warning . . . . . . . . . . . . . . . . . . . 28
4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4x4 Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
A
Active Descent Control (ADC)
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
ADC 4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . 48
ADC AWD Mode (Utility Edition
and UTE Models) . . . . . . . . . . . . . . . . . . . . . 51
Age 16 Warning . . . . . . . . . . . . . . . 25-26, 33
Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 13
Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 138
All Wheel Drive System. . . . . . . . . . . . . . . 48
All Wheel Drive System (Utility
Edition and UTE models) . . . . . . . . . . . 50
Automatic Transmission Gear
Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Auxiliary Foot Brake . . . . . . . . . . . . . 44, 115
Auxiliary Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . 39
AWD Mode (Utility Edition and
UTE models). . . . . . . . . . . . . . . . . . . . . . . . . . . 50
AWD Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
C
Camber and Caster. . . . . . . . . . . . . . . . . . 136
Cargo Box Dumping (X2 and
UTE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Cargo Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 85
Clean the Exterior . . . . . . . . . . . . . . . . . . . . 138
Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Clutch Cover Warning. . . . . . . . . . . . 27, 33
Cold Weather Operation. . . . . . . . . . . . . . 74
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . 113
Crankcase Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Crossing Hillsides . . . . . . . . . . . . . . . . . . . . . . 16
D
Descending Hills Improperly . . . . . . . . 16
Diagnostic Display Code
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Discretionary Warning . . . . . . . 26-27, 31
Disengaging Active Descent
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Drive Belt Wear/Burn. . . . . . . . . . . . . . . . 167
Driving in Reverse . . . . . . . . . . . . . . . . . . . . . 82
Driving on a Sidehill (Sidehilling) . . . 81
Driving on Slippery Surfaces . . . . . . . . 76
Driving Over Obstacles . . . . . . . . . . . . . . . 78
Driving Through Water. . . . . . . . . . . . . . . . 77
Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
B
Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Battery Charging . . . . . . . . . . . . . . . . . . . . . 135
Battery Maintenance . . . . . . . . . . . . . . . . 139
Battery Removal. . . . . . . . . . . . . . . . . . . . . . 132
Battery Storage . . . . . . . . . . . . . . . . . . . . . . . 135
Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Box Warning (X2) . . . . . . . . . . . . . . . . . . . . . . 35
Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . 44
Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Brake System Break-in . . . . . . . . . . . . . . . 70
Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
E
Electromagnetic Interference . . . . . 101
Electronic Power Steering (EPS). . . 47
Emissions Limited Warranty. . . . . . . 176
Engaging 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Engaging Active Descent
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Engine and Drivetrain Break-in . . . . . 70
Engine Backfires . . . . . . . . . . . . . . . . . . . . . 168
Engine Doesn't Turn Over . . . . . . . . . 168
Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Engine Pings or Knocks . . . . . . . . . . . . 169
Engine Runs Irregularly, Stalls
or Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
181
Engine Stop Switch . . . . . . . . . . . . . . . . . . . . 38
Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . 84
Engine Stops or Loses Power . . . . 170
Engine Turns Over, Fails to
Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
European Vibration and Noise . . . . . . . . 9
Exhaust Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Exported Products . . . . . . . . . . . . . . . . . . . 175
Exposure to Exhaust . . . . . . . . . . . . . . . . . . 14
Extreme Use Battery . . . . . . . . . . . . . . . . . . 48
Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 12
F
Failure to Inspect Before
Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Fluid Part Numbers . . . . . . . . . . . . . . . . . . 165
Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 139
Footwell Removal (1-Up
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 116-117
Front Gearcase (Demand
Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Front Wheel Hub Tightening . . . . . . . 117
Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . 138
Fuel Transport Warning. . . . . . . . . . . 30-31
Fuel Transport Warning (6x6
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Fuse Replacement. . . . . . . . . . . . . . . . . . . 121
Headlight Lamp Replacement . . . . 122
Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 39
Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High Beam Adjustment . . . . . . . . . . . . . 123
Hot Exhaust Systems . . . . . . . . . . . . . . . . . 21
How To Obtain Warranty
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
I
Ignition Switch/Light Switch . . . . . . . . . 37
Improper Cargo Loading . . . . . . . . . . . . . 20
Improper Hill Climbing . . . . . . . . . . . . . . . . 16
Inspect and Lubricate . . . . . . . . . . . . . . . 139
Instrument Cluster
Back Light Color . . . . . . . . . . . . . . . . . . . . . 60
Back Light Level . . . . . . . . . . . . . . . . . . . . . 61
Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Diagnostic Code. . . . . . . . . . . . . . . . . . . . . 63
Display Area 1 . . . . . . . . . . . . . . . . . . . . . . . 54
Display Area 2 . . . . . . . . . . . . . . . . . . . . . . . 55
Indicator Lamps . . . . . . . . . . . . . . . . . . . . . 53
Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 56
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Service Hours . . . . . . . . . . . . . . . . . . . . . . . . 62
Unit Selection Distance . . . . . . . . . . . . 57
Unit Selection Temperature. . . . . . . 58
J
Jumps and Stunts . . . . . . . . . . . . . . . . . . . . . . 16
G
General Warning . . . . . . . . . .22-23, 29-30
Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
H
Hand Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Handling Gasoline . . . . . . . . . . . . . . . . . . . . . 14
Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Headlight Housing
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 124
182
K
Know Your Riding Area/Tread
Lightly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
L
Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Limited Warranty . . . . . . . . . . . . . . . . . . . . . 171
Low Beam Adjustment . . . . . . . . . . . . . . 124
Lower Headlamp Replacement. . . 124
Lubricants / Service Products . . . . . 165
Lubrication Guide . . . . . . . . . . . . . . . . . . . . 107
M
Maintenance Chart . . . . . . . . . . . . . . . . . . 104
Maintenance Log. . . . . . . . . . . . . . . . . . . . . 179
Master Cylinder/Brake Fluid . . . . . . . . . 42
Mode/Reverse Override Switch . . . . 38
Modifications to Vehicle . . . . . . . . . . . . . . 21
N
New Operator Driving
Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Noise Emission Control
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
O
Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Oil and Filter Change. . . . . . . . . . . . . . . . 109
Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . 110
Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Oil Recommendations . . . . . . . . . . . . . . 108
Operating at Excessive Speeds . . . . 15
Operating Improperly in Reverse. . . 18
Operating in Unfamiliar Terrain . . . . . 18
Operating on Frozen Bodies of
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating on Pavement . . . . . . . . . . . . . . 14
Operating on Public Roads . . . . . . . . . . 15
Operating on Slippery Terrain . . . . . . . 18
Operating on Steep Hills . . . . . . . . . . . . . 18
Operating Over Obstacles . . . . . . . . . . . 19
Operating Through Water . . . . . . . . . . . . 19
Operation on Public Lands in
the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
P
Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Parking on an Incline . . . . . . . . . . . . . . . . . . 83
Parking the Vehicle . . . . . . . . . . . . . . . . . . . . 84
Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 165
Passenger Seat (X2) . . . . . . . . . . . . . . . . . . 47
Passenger Seat Backrest
(Touring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Passenger Warning . . . . . . . . . . . . . . . . . . . 31
Passenger Warning (6x6
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Passenger Warning/
Discretionary Warning (2-Up
Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Periodic Maintenance . . . . . . . . . . . . . . . 103
Physical Control of the Vehicle . . . . . 15
Physical Skills. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Polaris Products . . . . . . . . . . . . . . . . . . . . . . 165
Polishing the Vehicle . . . . . . . . . . . . . . . . 137
Poor Visibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Power Steering Unit (Cleaning). . . . 113
Pre-Ride Checklist . . . . . . . . . . . . . . . . . . . . . 71
Protective Apparel . . . . . . . . . . . . . . . . . . . . . 14
PVT Break-in (Clutches/Belt) . . . . . . . 70
PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
R
Rack Alert (7181584) . . . . . . . . . . . . . . . . . 35
Rack Alert, Front (X2) . . . . . . . . . . . . . . . . . 35
Rack/Box Warning . . . . . . . . . . . . . . . . . . . . . 26
Radiator Coolant . . . . . . . . . . . . . . . . . . . . . . 114
Rear Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Recovery Bottle Coolant . . . . . . . . . . . . 114
Registration, Warranty . . . . . . . . . . . . . . 171
Reverse Override/AWD
Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26, 34
S
Safe Operation Practices . . . . . . . . . . . . 72
Safe Riding Gear . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Labels and Locations . . . . . . . . 22
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Safety Training. . . . . . . . . . . . . . . . . . . . . . . . . . 11
Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . 13
Safety, Winch Maintenance. . . . . . . . 100
Seat Conversion. . . . . . . . . . . . . . . . . . . . . . . . 47
Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Severe Use Definition . . . . . . . . . . . . . . . 103
183
Shock Loading the Winch . . . . . . . . . . . . 99
Side Panel Removal. . . . . . . . . . . . . . . . . . 116
Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Skidding or Sliding . . . . . . . . . . . . . . . . . . . . . 19
Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . 128
Spark Plug Inspection. . . . . . . . . . . . . . . 126
Spark Plug Recommendations . . . 126
Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Specifications . . . . . 141, 147, 152, 154,
157, 159, 161
Specifications (450 HD 2x4). . . . . . . 143
Specifications (450 Utility
Edition) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Specifications (570 HD) . . . . . . . . . . . . 150
Stabilize the Fuel . . . . . . . . . . . . . . . . . . . . . 138
Stalling While Climbing a Hill . . . . . . . . 17
Starting the Engine . . . . . . . . . . . . . . . . . . . . 73
Steering Assembly. . . . . . . . . . . . . . . . . . . . 113
Stopping the Engine . . . . . . . . . . . . . . . . . . . 84
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
T
Taillights/Brake Lights
Replacement . . . . . . . . . . . . . . . . . . . . . . . . 125
Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Tire Pressure/Load Warning. . . 27, 3233
Tire Pressure/Load Warning
(6x6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tire Pressure/Load Warning
(Touring) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . . 117
Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Toe Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 120
Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Towing Your Vehicle . . . . . . . . . . . . . . . . . . . 89
Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Trailering Your Vehicle . . . . . . . . . . . . . . . . 89
Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . 111
Transporting the ATV. . . . . . . . . . . . . . . . 140
TURF Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Turning Around on a Hill (KTurn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
184
Turning Improperly. . . . . . . . . . . . . . . . . . . . . 15
U
Unauthorized Use of the Vehicle . . . 21
V
Vehicle Break-in Period. . . . . . . . . . . . . . . 69
Vehicle Identification Numbers . . . . . 10
Vehicle Immersion . . . . . . . . . . . . . . . . . . . 127
W
Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . 8
Washing the Vehicle. . . . . . . . . . . . . . . . . 137
Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . 126
Wheel Installation . . . . . . . . . . . . . . . . . . . . . 118
Wheel Nut Torque
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 119
Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . . 118
Winch Cable Care . . . . . . . . . . . . . . . . . . . . . 98
Winch Maintenance and
Service Safety . . . . . . . . . . . . . . . . . . . . . . . 100
Winch Operation . . . . . . . . . . . . . . . . . . . . . . . 93
Winch Safety Precautions . . . . . . . . . . . 91
Winch Shock Loading . . . . . . . . . . . . . . . . . 99
WARNING
Improper vehicle use can result
in SEVERE INJURY or DEATH.
ALWAYS USE
AN APPROVED
HELMET AND
PROTECTIVE
GEAR FOR
DRIVER AND
PASSENGER
NEVER
USE ON
PUBLIC
ROADS
NEVER
CARRY
PASSENGERS
ON A
1-UP ATV
(TYPE I)
NEVER
CARRY MORE
THAN 1
PASSENGER
ON A 2-UP
ATV (TYPE II)
NEVER
USE WITH
DRUGS OR
ALCOHOL
NEVER operate:
• without proper ATV training or instruction.
• at speeds too fast for your skills or the conditions.
• on public roads - a collision can occur with another vehicle.
• (Type I / 1-Up ATV only) with a passenger – passengers affect balance
and steering and increase risk of losing control
• (Type II / 2-Up ATV only) with a passenger unless passenger seat
is securely in place
THE OPERATOR MUST ALWAYS:
• use proper riding techniques to avoid vehicle overturns on hills
and rough terrain and in turns.
• avoid paved surfaces - pavement may seriously affect handling
and control.
• (Type II / 2-Up ATV only) reduce speed and use extra caution at all times
when carrying a passenger – dismount passenger when conditions require
• (Type II / 2-Up ATV only) make sure passenger reads and understands
all safety labels
READ OWNER'S MANUAL.
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. 9929536 Rev 02
Printed in USA
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