ATV or Youth Sportsman Forest 550 / Sportsman Forest 850 2011 Owner's Manual

Sportsman Forest 550

Sportsman Forest 850

Owner's Manual for Maintenance and Safety

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Before you operate this vehicle, read the owner’s manual

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy 55

Medina, MN 55340

Phone 1-888-704-5290

Part No. 9923176 Rev 01

Printed in USA

*9923176 *

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER ® utility vehicles

• Victory Motorcycles ®

Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service

Dealer ® (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.

For more information about POLARIS, visit us online at www.polarisindustries.com.

1

POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS

Industries Inc.

MAXXIS ® is a registered trademark of Maxxis International.

Copyright 2010 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.

Printed in U.S.A.

SPORTSMAN Forest 550 / SPORTSMAN Forest 850 Owner’s Manual

P/N 9923176

2

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Emission Control Systems . . . . . . . . . . . . . . . 67

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 121

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 125

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 126

Declaration of Conformity . . . . . . . . . . . . . . . 130

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

3

4

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.

INTRODUCTION

As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly.

Know all laws and regulations concerning the operation of this vehicle in your area.

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank

(using your key number) and mating it with one of your existing keys.

The ignition switch must be replaced if all keys are lost.

VIN

Engine Serial Number

Key

Number

####

550 850

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

5

6

SAFETY

WARNING

Failure to follow the warnings in this manual can result in serious injury or death.

This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating this POLARIS vehicle.

Safety Training

When you purchased your new POLARIS vehicle, your dealer offered a hands-on safety training course. You were also provided with printed materials that explain safe operating procedures. Review this information on a regular basis.

If you purchased a used POLARIS vehicle from a party other than a

POLARIS dealer, please request free safety training from any authorized POLARIS dealer.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Restrictions

This vehicle is approved for OFF-ROAD TOWING ONLY. Towing a trailer with this vehicle on public roads is prohibited. See your

POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

Equipment Modifications

The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only

POLARIS-approved accessories. Know their function and effect on the vehicle.

SAFETY

Rider Safety

WARNING

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.

Never operate this vehicle without proper instruction.

Take a training course.

Beginners should receive training from a certified instructor. Contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.

Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

7

8

SAFETY

Rider Safety

Never carry a passenger on this vehicle.

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating this vehicle.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

Rider Safety

Always inspect your vehicle before each use to verify that it's in safe operating condition.

See page 44. Follow the inspection and maintenance procedures outlined in this manual.

Keep both hands on the handlebars. Keep both feet on the footrests.

SAFETY

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for turning. See page 47.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

If the vehicle has been involved in an accident, always have an authorized

POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

9

SAFETY

Rider Safety

Never attempt jumps or other stunts.

Always follow the procedures outlined in this manual for driving on hills. See page 52.

Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.

Avoid climbing hills steeper than 25



.

Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 55.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 54.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. See page 56.

10

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 53.

Always follow the procedures outlined in this manual for operating over obstacles. See page 50.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 48.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page

49.

Always follow the procedures outlined in this manual for driving in reverse. See page 51.

11

SAFETY

Rider Safety

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Never modify this vehicle through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

12

SAFETY

Rider Safety

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 26.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about safety, contact an authorized

POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.

13

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Long

Sleeves

Eye Protection

Gloves

Long Pants

Boots

Helmet

Always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

E 4

051039

0006.31

14

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

15

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 a 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.

The following pages repeat the information found on each label.

2x4



OUT

IN





General

Alert

Reverse

Override

Warning

Age 16

Alert



Hill

Operation

Alert

16

SAFETY


General Alert

(Multi-Lingual)

Before you operate this vehicle, read the owner’s manual.

7173025

Reverse Override Warning/4X4 Caution

WARNING

Improper use of the override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually, while in reverse.

CAUTION

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

7175512

Hill Operation Alert

• Never operate this vehicle on HILLS steeper than 25 degrees 25



.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

7173026

17

SAFETY


“No Passenger”

Warning

Tire

Pressure/Load

Warning

“No Passenger” Warning

WARNING

NEVER ride as a passenger.

Passengers can cause a loss of control, resulting in SEVERE INJURY or

DEATH.

7175378

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (KPa):

Front: 7.0 psi (48.3 kPa)

Rear: 5.0 psi (34.5 kPa)

MAXIMUM WEIGHT CAPACITY 575 lbs. (261 kg)

INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND

ACCESSORIES.

7175820

18


Rack

Warning





Clutch Cover

Warning

(under seat)

Clutch Cover Alert



SAFETY

Rack

Warning

7175826

Rack Warning, Front and Rear

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.

• Max. Rack Loads: Front 120 lbs. (54 kg) Rear 240 lbs. (109 kg)

7175448

19

FEATURES AND CONTROLS

Switches

Momentary High-Beam

Switch

2x4

OUT

IN

Mode/Reverse

Override Switch

Winch

Switch

4X4 Switch

Main Key

Switch

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch.

Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override switch.

The reverse override switch also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override switch as a MODE button.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 30. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

Momentary High Beam Switch

Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released.

Winch Switch

See page 61 for winch information.

20


Switches

Main Key Switch

End all electrical power to the vehicle.

LIGHTS ON position turns the headlights on.

Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the POSITION

LIGHTS ON position.

See page 45 for starting procedures.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

Headlight

Switch

Engine

Stop

Switch

OFF

RUN

Headlight Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam

Hazard

Switch

Override

Switch

Horn

Switch

Turn

Signal

Switch

Low Beam

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position to end the signal.

Horn Switch

Press the horn switch to sound the horn

Hazard Warning Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

21


Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving.

Throttle Lever

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Press the throttle lever to increase engine speed and vehicle movement.

Release the lever to reduce engine speed and vehicle movement.

Electronic Throttle Control

2x4

Electronic Throttle Control (ETC)

ETC causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction. Do not modify the ETC system or replace it with other throttle mechanisms.

22


Brakes

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes.

Press the brake pedal down with your foot to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

Foot

Brake

Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

23


Brakes

Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake lever two or three times, then squeeze and hold.

3. Push the parking brake lock forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake lever.

Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

24


Electronic Power Steering (EPS)

Electronic power steering engages when the ignition key is turned to the

ON position. EPS remains engaged whether the vehicle is moving or idle. See page 33 for EPS Warning Indicator information.

Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

Gear

Selector

Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for extended periods and when operating uphill at a slow speed.

25


Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full left position.

Tip: The handlebars may also be locked in the full left position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key.

Tip: Place the steering lock keys in a safe place. The lock must be replaced if the keys are lost.

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

Fuel Tank

Always refuel with the engine stopped, and outdoors or in a well ventilated area.

Refuel on a level surface.

Remove the fuel tank cap and add fuel.

Use either leaded or unleaded gasoline with a minimum pump octane number of

87=(R+ M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.

Fuel Tank

Cap

26


Front Rack/Compartment

Release the front rack latches and remove the rack to gain access to the front compartment. To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches.

Access the following components in the front compartment:

• Radiator cap

• Foot brake fluid reservoir

• ADC fluid reservoir

• Coolant recovery bottle cap

• Electrical/fuse/relay components

Latches

Brake Fluid Reservoir

ADC Fluid Reservoir

Coolant

Bottle Cap

Radiator

Cap

Electrical/Fuse/Relay

27


All Wheel Drive System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4 Mode

ADC 4X4

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

See page 30.

4X4 Mode

2x4

When the switch is on 4X4, the vehicle is in 4X4, 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.

2x4

4X4

Switch

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 vehicle is in two-wheel drive at all times.

28


All Wheel Drive System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving.

Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to

4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

29


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

30


Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle speed from a gear in the transmission. The instrument cluster measures distance in miles/kilometers as well as hours of operation.

In addition to showing vehicle speed, the instrument cluster also displays the following items: engine speed, odometer, resettable trip meters

(2), total engine hours of operation, service interval timer and indicator, gear position, fuel level, AWD status, EPS status, high beam status, battery voltage warning, temperature warning and diagnostic display mode.

These features are outlined on the following pages.

Directional

Indicator

Rider Information Center

High Beam

Indicator

EPS Warning

Indicator

Neutral

Indicator

Over-Temperature

Indicator

NOTICE: High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

31



Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, please see your POLARIS dealer.

The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 35.

2 3

1

4

13

12

6

11

7 9

5 8

10

1.

Gear Indicator - This indicator displays gear shifter position.

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

-- = Gear Signal Error (or shifter between gears)

2.

Information Display Area - This area displays odometer, tripmeters, engine hour meter and programmable service hour interval.

3.

Speed Display - This area displays vehicle ground speed or engine rotational speed when the corresponding display is selected. See page 34.

32




4.

Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer.

5.

High Beam Indicator - This indicator appears when the lights are set to high beam.

6.

Clock - The clock displays time in a 12-hour or 24-hour format. If the engine is turned off, press the MODE button. The time will display for 5-10 seconds. See page 36 for resetting instructions.

7.

Engine Overheat Warning - This indicator flashes to indicate an overheated engine. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine power.

8.

Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 36 for resetting instructions.

9.

Under / Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged.

It may also occur when the engine is at idle and high electrical load

(lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

10.

Check Engine Warning Indicator - This indicator appears if an

EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. See your dealer.

11.

4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is on either ADC 4X4 or 4X4).

12.

EPS Warning Indicator - This indicator illuminates when the key is turned to the ON position and goes off when the engine is started.

If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service.

13.

Directional Indicator - This indicator illuminates when the hazard switch or a turn signal switch is turned on.

33




Speed Display Area

Use the MODE button to toggle through the speed display options.

MODE button operation is locked out at speeds above approximately

15 MPH (25 km/h).

Tip: The reverse override switch also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override switch as a MODE button.

This feature does not contain a vehicle speed lockout function and can be used at any operating speed.

MODE

Button

SELECT

Button

Ground Speed Mode

Ground speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h).

Engine Speed Mode

Engine speed is displayed in revolutions per minute (RPM).

34




Information Display Area

Use the SELECT button (SEL) to toggle through the information area options. SELECT button operation is locked out at speeds above approximately 15 MPH (25 km/h).

Tip: The reverse override switch also acts as the SELECT button when pressed and released quickly. The transmission cannot be in reverse when using the override switch as a SELECT button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.

Standard/Metric Display

The display can be viewed in either standard or metric units of measurement. To change units:

1. Press and hold the MODE button until vehicle speed is displayed.

2. Toggle through the information area using the SELECT button until the odometer is displayed.

3. Press and hold the MODE button until the displayed units change.

Release the button.

4. New settings remain until changed using the same procedure.

12-Hour/24-Hour Clock Display

1. Press and hold the MODE button until RPM is displayed.

2. Toggle through the information area using the SELECT button until the odometer is displayed.

3. Press and hold the MODE button until the clock displays the new clock format (either 24-hour or 12-hour). Release the button.

4. New settings remain until changed using the same procedure.

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meters record the distance traveled by the vehicle on each trip if reset before each trip. To reset a trip meter, select the trip meter 1 or trip meter 2 mode. Press and hold the MODE button on the instrument cluster until the total changes to 0. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

35





Programmable Service Interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval.

1. Press the SELECT button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the SELECT button to advance the hours to the desired setting (including OFF). When the digits stop flashing, the interval has been set.

Clock Mode

Use one of the following two methods to reset the clock.

Method 1

1. Select the Hour Meter Mode.

2. Press and hold the mode button on the instrument cluster until the hour display flashes. Release the button.

3. Press and release the SELECT button to advance the hours.

4. After the hours are set, press and release the MODE button to move to the minutes. Use the same procedure to reset the minutes.

5. When the digits stop flashing the clock has been set.

Method 2

1. With the key turned off, press and hold the MODE button.

2. While still holding the MODE button, turn the key to the ON position.

3. Continue to hold the MODE button until the hour display flashes.

Release the button.

4. Set the time as outlined in steps 3-5 of Method 1.

36





Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only.

Please see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit. Please see your

POLARIS dealer to retrieve inactive codes.

Use the following procedure to view active codes that occur when the key is on.

1. Place the transmission in PARK.

2. Press and release the SELECT button until the flashing check engine warning indicator appears in the display.

3. A set of two numbers will also appear in the display.

• The 2-6 digit suspect parameter number (SPN) in the information area indicates which component is generating the fault code.

• The 1-2 digit failure mode indicator (FMI) number in the clock area indicates the fault mode, such as open or short circuit.

4. See pages 38-41 for code definitions and failure descriptions.

Tip: More than one fault may be active. Press and hold the MODE button to toggle through all currently active diagnostic codes.

37




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.

SPORTSMAN Forest 550 Diagnostic Codes

Component

Throttle Position Sensor

Engine Temperature Sensor

Intake Air Temperature Sensor

Manifold Absolute Pressure Sensor

Crankshaft Position Sensor

Gear Sensor Signal

Injector 1 (MAG)

Condition

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Temperature Too High

Engine Overheat Shutdown

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Circuit Fault

Voltage Too Low (to Calibrate)

Voltage Too High

Signal Fault

Driver Circuit Open/Grounded

Driver Circuit Short to B+

Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded


Fuel Pump Driver Circuit Driver Circuit Open/Grounded


Fan Relay Driver Circuit Driver Circuit Open/Grounded


523

523

523

651

651

105

105

102

102

636

SPN

51

51

110

110

110

110

1268

1268

1347

1347

1071

1071

2

5

4

3

3

3

4

3

4

8

FMI

3

4

3

4

16

0

5

3

5

3

5

3

38





Component

Idle Air Control

Starter Enable Circuit

All Wheel Drive Control

System Power

Throttle Safety Signal

Active Descent Control System

Steering Over Current Shut Down

Steering Excessive Current Error

Condition

Driver Circuit Grounded

Shorted Load*



Voltage Too High

Voltage Too low

Voltage Too High

Voltage Too Low

Signal Out of Range

Throttle Stuck


Current Above Normal or

Grounded

Current Above Normal or

Grounded

T1 Shorted to Ground

T1 Shorted to Bus

SPN

520193

520207

168

168

520194

520194

520194

520194

520203

520221

520222

FMI

5

520193 11

1321 3

3

7

3

6

3

4

3

4

2

6

Steering Torque Sensor T1 Partial

Failure


Failure


T2 Shorted to Bus

Steering Torque Sensor Full Failure T1 and T2 Shorted to Ground

T1 and T2 Shorted to Bus

T1 Shorted to Ground & T2

Shorted to Bus


Shorted to Bus

T1 and T2 are Shorted

Steering Position Sensor P1 Partial

Failure

Steering Position Sensor P2 Partial

Failure

P1 Shorted to Ground

P1 Shorted to Bus


P2 Shorted to Bus

Steering Position Sensor Full Failure P1 and P2 Shorted to Ground

EPAS Inverter Temperature

EPAS CAN Communications

Receive Error

EPAS CAN Communications

Transmit Error

P1 and P2 Shorted to bus

Greater than 110 Degrees C

520228 3

520229 16

Greater than 120 Degrees C 520229

No RX Message for 2 Seconds 520230

0

9

No TX Message for 2 Seconds

520223

520223

520224

520224

520225

520225

520225

520231

4

520225 16

520225

520226

520226

520227

520227

520228

4

3

3

4

3

17

2

4

3

4

3

4

9

*Assumes unipolar configuration of stepper motor

39





Component

Throttle Position Sensor

Engine Temperature Sensor

Condition

Voltage Too High

Voltage Too Low

Voltage Too High

Voltage Too Low

Intake Air Temperature Sensor

Temperature Too High

Engine Overheat Shutdown

Voltage Too High

Voltage Too Low

Manifold Absolute Pressure Sensor Voltage Too High

Crankshaft Position Sensor

Vehicle Speed Signal

Gear Sensor Signal

Injector 1 (MAG) (SDI Part Load)

Voltage Too Low

Signal Out of Range

Circuit Fault

Plausibility Fault

Speed Too High

Plausibility Fault

Voltage Too Low

Voltage too high

Signal fault


Injector 2 (PTO) (SDI Part Load)

Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+

Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+

Fuel Pump Driver Circuit Driver Circuit Open/Grounded



Fan Relay Driver Circuit






Idle Air Control

Starter Enable Circuit







Position Out of Range




1071

1071

1071

634

634

634

634

1321

1321

1321

651

651

652

652

652

1268

1269

1347

1347

1347

84

523

523

523

651

102

102

636

636

84

110

110

105

105

102

SPN

51

51

110

110

5

3

4

7

4

4

5

5

3

3

5

3

3

3

4

5

3

3

4

4

3

2

2

4

5

8

2

4

2

8

16

0

3

4

3

FMI

3

4

3

4

40





Component

Chassis Relay

All Wheel Drive Control

System Power

Throttle Safety Signal

Condition







Voltage Too High

Voltage Too low

Voltage Too High

SPN

520208

520208

520208

520207

520207

520207

168

168

520194

Active Descent Control System

Voltage Too Low

Signal Out of Range

Throttle Stuck



520194

520194

520194

520203

520203

Idle Speed


Speed Too High

520203

520211

Speed Too Low 520211

Steering Over Current Shut Down Current Above Normal/Grounded 520221

Steering Excessive Current Error Current Above Normal/Grounded 520222


Failure


Failure

Steering Torque Sensor Full

Failure


T1 Shorted to Bus


T2 Shorted to Bus

T1 and T2 Shorted to Ground

520223

520223

520224

520224

520225

520225 3

520225 16

Steering Position Sensor P1

Partial Failure

Steering Position Sensor P2

Partial Failure

T1 and T2 Shorted to Bus


Shorted to Bus


Shorted to Bus

T1 and T2 are Shorted


P1 Shorted to Bus


520225

520225

520226

520226

520227

4

3

4

3

4

4

6

6

4

3

17

Steering Position Sensor Full

Failure

EPAS Inverter Temperature

P2 Shorted to Bus

P1 and P2 Shorted to Ground

P1 and P2 Shorted to bus



520227

520228

3

4

520228 3

520229 16

520229 0

3

4

2

4

EPAS CAN Comm. Receive Error No RX Message for 2 Seconds

EPAS CAN Comm. Transmit Error No TX Message for 2 Seconds

520230

520231

9

9

7

5

4

2

3

3

4

3

4

3

FMI

5

3

4

5

41

OPERATION

Failure to operate the vehicle properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Break-In Period

The break-in period for your new POLARIS vehicle is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

NOTICE: Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

42

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 26. Always exercise extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 73. Add oil if necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist. See page 44.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours, one month or 500 miles (800 km), whichever comes first.

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.

43

OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item

Hand brake/lever travel

Foot brake

Brake fluid

Front suspension

Rear suspension

Steering

Tires

Wheels/fasteners

Remarks

Ensure proper operation


Ensure proper levels

Inspect, lubricate if necessary

Inspect, lubricate if necessary

Ensure free operation

Inspect condition and pressure

Inspect, ensure fastener tightness

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil Ensure proper levels

Coolant level

Coolant hoses

Throttle

Indicator lights/switches

Engine stop switch

Air filter, pre-filter

Headlamp

Brake light/tail lamp

Riding gear

ADC Fluid

Mirrors

Winch

Ensure proper level

Inspect for leaks




Inspect, clean

Check operation

Check operation

Wear approved helmet, goggles, and protective clothing

Ensure proper level

Adjust for best side/rear vision

Inspect cable and switch.

78

-

62-63

Page

22

98

20

21

26

73

83

84

-

92

21

97

14

72

-

90

90

91

-

87

87

85

72

44

OPERATION

Starting the Engine

1. Position the vehicle on a level surface


Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.

3. Sit on the vehicle. Move the engine stop switch to RUN.

4. Do not press the throttle while starting the engine.

5. Turn the ignition key past the POSITION LIGHTS ON position to engage the starter. Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

6. If the engine does not start, return the key to the OFF position and wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.

Cold Weather Operation

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

45

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 14.

2. Perform the pre-ride inspection. See page 44.


4. Mount the vehicle from the left side.

5. Sit upright with both feet on the footrests. Keep both hands on the handlebars.

6. Start the engine and allow it to warm up.

7. Apply the brakes.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the brakes.

11. Slowly depress the throttle with your right thumb and begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.

46

Turning the Vehicle

1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn.

Activate the right signal before a right turn.

2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest.

Use the same leaning technique for turning in reverse.

3. Practice making turns at slow speeds before attempting to turn at faster speeds.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

OPERATION

47

OPERATION

Driving on Slippery Surfaces

Sideways

Skid

Turn in direction of skid

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down when entering slippery areas.

2. Engage 4X4 before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.

3. Be alert. Watch the trail. Avoid quick, sharp turns

4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

48

OPERATION

Driving Through Water

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoid-

Maximum

Depth able, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

NOTICE: If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

5. Wet brakes may have reduced stopping ability. Dry the brake pads by driving slowly and applying the brakes lightly several times until braking action is normal.

6. If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page

103. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

49

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Always follow the procedures outlined in this manual for operating over obstacles.

50

Driving in Reverse

OPERATION

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use with caution.

NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

51

OPERATION

Driving Uphill

25



Maximum

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30.

2. Drive straight uphill.

3. Avoid steep hills (25



maximum).

4. Avoid hills with slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

52

OPERATION

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

3. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

4. Use the K-turn to turn around. See page 56.

Always follow the procedures outlined in this manual for driving on hills. Avoid climbing hills steeper than 25



.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

53

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Shift body weight uphill.

3. Keep your feet on the footrests.


5. Avoid crossing the sides of steep hills.

6. If the vehicle begins to slide or tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately !

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

54

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page

30.


3. Never drive downhill at high speed. Slow down.

4. Drive straight downhill.

Avoid driving downhill at an angle, which can cause the vehicle to pitch sharply to one side.

5. Shift your weight rearward.

6. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

OPERATION

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

55

OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill!

Use the K-turn to turn around.

2.4 m

1. Stop the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 30.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake.

8. Slowly release the brake lever and allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

56

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill.

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake.

14. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.

Always follow the procedures outlined in this manual for driving on hills. See page 52.

Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills.

Avoid climbing hills steeper than 25



.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

57

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo.

• Read and understand the load distribution warnings listed on the vehicle warning labels.

• Never exceed the stated load capacity for this vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• 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.

• TOWING is approved OFF-ROAD ONLY.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

58

OPERATION

Hauling Cargo

Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of this manual.

2/3

1/3

Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Use low forward gear when hauling or towing heavy cargo to extend belt life.

Towing Loads

Towing is approved OFF-ROAD ONLY. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

• Do not tow any trailer on a grade steeper than 15



• Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer.

• If towing a load, reduce rear 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 vehicle warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARISapproved (or equivalent) accessories designed for use on this vehicle.

Maximum

10 cm

59

OPERATION

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Stop the engine.


3. Always block the rear wheels on the downhill side.

60

WINCH GUIDE

The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and operating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people.

Winch Safety Precautions

1. Be alert. Do not operate the winch under the influence of drugs, alcohol or medication.

2. Practice using the winch so you are prepared to use it in an emergency situation.

WARNING

Never connect DC powered winches to AC current. Motor damage or fatal shock may occur.

DANGER

Stand clear of the cable and load during winching. Keep helpers and spectators at a safe distance. If a cable pulls loose or breaks under the load, it can lash back with dangerous force.

3. Beware of the danger zone.

The danger zone is the area of the rotating wire cable drum, the fairlead (if fitted), the cable, the hook and the motor. Before placing hands in or near the danger zone, first relieve tension on load, then disconnect the control switch.

Danger Zone

4. If you are within four feet of the winch, do not hold the cable and the remote (if equipped) at the same time.

61

WINCH GUIDE

Winch Cable Care

1. The life of a cable is directly related to the care it receives. The wire cable on a new winch (and any replacement cables) must be respooled under a minimum of a 100-lb. (45.4-kg) load before use.

Failure to do this will result in cable damage.

2. Inspect all cable before use. Mashed, pinched, frayed or kinked areas severely reduce the load-carrying capability. Replace damaged cable promptly.

3. Prevent kinks before they occur.

A.

This is a start of a kink. Straighten the cable before using it.

B.

The cable was pulled and the loop has tightened to a kink. The cable is now permanently damaged and should not be used.

C.

The result of kinking is that each strand pulls a different amount of load, causing the strands under the greatest tension to break. This reduces the load capacity of the entire cable.

A

B

C

4. Before re-spooling, remove all load from the cable. Hold the handlebar switch lead in one hand and the cable in the other. Move away from the vehicle as far as the switch will allow. Activate the switch, walk in several feet of cable, then release the switch. Repeat this process until the re-spooling is complete.

CAUTION!

To avoid injury, always release the switch before your hand comes within four feet of the fairlead (the physical opening through which the cable passes).

5. Be sure the cable is distributed evenly and tightly on the drum. A loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged.

6. Do not grease or oil the cable. Doing so causes dirt contamination that will reduce the life of the cable.

62

WINCH GUIDE

Winch Preparation and Inspection

DANGER

Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

WARNING

Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose connections. A damaged, shortened lead could cause the winch to operate as soon as it is plugged in.

DANGER

Never touch the cable or hook while they are in tension or under load. Even at rest, the winch may have the cable in tension. Never guide a cable under tension onto the drum with your hand.

1. Winch with at least five wraps of cable around the winch drum. With fewer wraps, the cable could pull loose from the drum under load.

63

WINCH GUIDE

Winch Rigging

WARNING

Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch.

1. Use a nylon sling to attach the cable to an anchor point.

CAUTION!

Do not attach the hook back onto the cable. Doing so can cause the cable to break.

WARNING

Always use a handsaver. Do not hold the hook with your hand. This is important not only when reeling cable in but also when removing cable from the winch under power.

2. Run the winch intermittently to take up cable slack. When using a pulley block, be sure the cable is running properly in all pulleys before applying a load.

CAUTION!

Never engage or disengage the clutch if the winch is under load, the cable is in tension or the drum is rotating.

64

WINCH GUIDE

Winch Operation

NOTICE: This winch is designed for intermittent use. Prolonged use may result in damage due to overheating.

1. Use common sense.

2. Take your time.

3. Think through the situation.

4. Pay attention to what is going on when you are winching.

5. DO NOT overheat the winch motor. During extended winching, stop and feel the winch motor. The motor should be cool enough to touch. If not, allow the motor to cool before continuing.

6. Extended winching will discharge your battery. If the low battery warning light comes on, stop winching. Make sure the transmission is in neutral or park, then rev the motor for a few minutes until the warning light goes out. Recharge the battery as soon as possible.

7. DO NOT overload or stall the winch. If the load is greater than the winch is capable of pulling, use a snatch block.

8. Avoid continuous side pulls.

9. Never tow the vehicle by the winch cable.

10. Never use the winch cable as a tie-down.

11. Use an anchor point that is stronger than what you are pulling.

12. DO NOT hook the cable back onto itself. This will damage the cable.

65

WINCH GUIDE

Winch Operation

13. Use as much cable as possible when pulling. Additional wraps of cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

14. Never pull with less than five wraps of cable on the spool.

15. Inspect the condition of the cable prior to pulling. If the cable is frayed or damaged, replace it as soon as possible.

16. DO NOT submerge the winch in water.

66

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrestor

Your POLARIS vehicle has a spark arrestor that was designed for onroad and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices

(such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

67

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine

POLARIS parts available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on page 135.

Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

Pay special attention to the oil level. A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase. Change oil immediately if the oil level begins to rise. Monitor the oil level, and if it continues to rise, discontinue use and determine the cause or see your dealer.

68

MAINTENANCE


Improperly performing the procedures marked with a  could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized POLARIS dealer perform these services.

Maintenance Chart Key



Perform these operations more often for vehicles subjected to severe use.

E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.)



Have an authorized POLARIS dealer perform these services.

69

MAINTENANCE


Perform all services at whichever maintenance interval is reached first.

Item

Steering

Front suspension

Rear suspension

Tires

Brake fluid level

Brake lever travel

Brake system

Wheels/fasteners



E

Frame fasteners

Engine oil level

Winch

Air filter, pre-filter

Coolant

Maintenance Interval

(whichever comes first)

Hours Calendar

-

-

-

-

-

-

-

-

-

-

-

-

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Pre-Ride

Daily

-

-

-

-

-

-

-

-

-

-

Miles

(Km)

-

-

Remarks

See Pre-Ride Checklist on page 44.



ADC fluid

-

-

Daily

Daily

-

-

See pages 62-63.

Inspect; clean often; replace as needed

Check level daily, change coolant every 2 years

Check level daily, add as needed

Inspect daily; clean often



Power steering unit

(if equipped)

Headlamp/taillight



E

Air filter, main element



Engine oil change

  Brake pad wear

-

-

-

20 H

10 H

Battery 20 H



Demand drive fluid 25 H



Demand drive fluid

(extreme use)



Rear gearcase oil



Transmission oil



General lubrication

25 H

25 H

25 H

50 H

Daily

Daily

Weekly

1 Month

Monthly

Monthly

Monthly

1 M

Monthly

Monthly

3 M

-

-

-

Check operation

Inspect; replace as needed

500 (800) Perform a break-in oil and filter change (see page 42)

100 (160) Inspect periodically

200 (320) Check terminals; clean; test

250 (400) Inspect level

250 (400) Change fluid every 25 hours if ADC is subjected to extreme use. See page 77.

250 (400)

250 (400)

500 (800)

Inspect level

Inspect level

Lubricate all fittings, pivots, cables, etc.



Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service

 Have an authorized POLARIS dealer perform these services.

70

MAINTENANCE


Item



E

Throttle Cable/

ETC Switch

Maintenance Interval

(whichever comes first)

Hours Calendar

50 H 6 M

Remarks

Miles

(Km)

500 (800) Inspect; adjust; lubricate; replace if necessary

E Throttle Body

Intake Duct

Drive belt

Cooling system

 Radiator 50 H

 Cooling hoses 50 H

 Engine oil change 100 H

 Demand drive fluid

(normal use)

100 H

 Rear gearcase oil 100 H

 Transmission oil 100 H

Fuel system 100 H

 Engine mounts

Exhaust muffler/ pipe



E

Spark plug



Wiring

50 H

50 H

50 H

100 H

100 H

100 H

100 H

6 M

6 M

6 M

6 M

6 M

6 M

12 M

12 M

12 M

12 M

12 M

12 M

12 M

12 M

500 (800) Inspect duct for proper sealing/air leaks

500 (800) Inspect; replace as needed

1000 (1600) Inspect coolant strength seasonally; pressure test system yearly

1000 (1600) Inspect; clean external surfaces

1000 (1600) Inspect for leaks

1000 (1600) Change the oil and filter

1000 (1600) Change fluid



1000 (1600) Check for leaks at tank cap, lines, filter, pump; replace lines every two years

1000 (1600) Inspect

1000 (1600) Inspect


100 H

100 H

12 M

12 M

1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.

1000 (1600) Inspect; clean; replace worn parts




E







Clutches (drive and driven)

Front wheel bearings







Brake fluid

ADC fluid

Spark arrestor

Valve clearance

Toe adjustment

Headlight aim

200 H

200 H

300 H

1000 H

24 M

24 M

36 M

-

-

-

2000 (3200) Change every two years

2000 (3200) Change every two years

3000 (4800) Clean out

10000

(16000)

Inspect; adjust

Inspect periodically; adjust when parts are replaced

Adjust as needed

71

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Recommended

Lubricant

550 Engine Oil PS-4 PLUS

Performance

Synthetic 2W-50

850 Engine Oil PS-4 PLUS

Performance

Synthetic 2W-50

Transmission

Oil

AGL PLUS

Transmission

Fluid

Demand Drive

Fluid (Front

Gearcase)

Demand Drive

Plus Fluid

Rear

Gearcase Oil

ATV Angle Drive

Fluid (or GL5 80-

90 weight gear lube)

Brake Fluid

ADC Fluid

DOT 4 Only

Demand Drive

Plus Fluid

Front Prop

Shaft Yoke

A-Arms, Front and Rear

Capacity at Fluid

Change

2 qt.

(1.9 l)

2 qt.

(1.9 l)

32 oz.

(950 ml)

9.3 oz.

(275 ml)

7.1 oz.

(210 ml)

---

---

Fill Plug

Torque

---

---

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs.

(11-14 Nm)

10-14 ft. lbs.

(14-19 Nm)

---

---

Drain Plug

Torque

15-17 ft. lbs.

(20-23 Nm)

12 ft. lbs.

(16 Nm)

10-14 ft. lbs.

(14-19 Nm)

11 ft. lbs.

(15 Nm)

10-14 ft. lbs.

(14-19 Nm)

---

---

Inspection

Procedure

Page 73.

Page 73.

Page 76.

Page 77.

Page 80.

Page 85.

Page 78.

POLARIS

Premium U-Joint

Lube

Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

POLARIS

Premium All-

Season Grease

Grease fittings after extreme use or if suspension becomes squeaky.

Front

Front Prop Shaft Yoke

72

MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See the table on page 72 for fluid recommendations, capacities and plug torques.

Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 125 for the part numbers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage. Always use the recommended oil. Never substitute or mix oil brands.

Oil Level

Check the oil level when the engine is cold. Never check the oil with the engine running.

Access the oil dipstick and fill tube from the left side of the vehicle.

1. Position the vehicle on a level surface. Place the transmission in PARK.

2. Remove the dipstick. Wipe it dry with a clean cloth.

3. Reinstall and tighten the dipstick.

4. Remove the dipstick and check the oil level.

5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

6. Reinstall and tighten the dipstick.

Full

Full

850

Dipstick

Add

Add

550

73

MAINTENANCE

Engine Oil

Oil and Filter Change

See the table on page 72 for fluid recommendations, capacities and plug torques. Always change the oil and filter at the intervals outlined in the

Periodic Maintenance Chart beginning on page 68. Always change the oil filter whenever changing oil.

550

Drain

Plug to front

850

Drain

Plug

Filter Access

1. Position the vehicle on a level surface. Place the transmission in

PARK.

2. Start the engine. Allow it to warm up at idle for two to three minutes.

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the crankcase.

6. Remove the drain plug. Allow the oil to drain completely.

Hot oil can cause burns to skin. Do not allow hot oil to contact skin.

7. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.

8. Reinstall the drain plug. Torque to specification.

74

MAINTENANCE

Engine Oil

Oil and Filter Change

9. Place shop towels beneath the oil filter. Using an oil filter wrench

(available from your POLARIS dealer), turn the filter counterclockwise to remove it.

10. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

11. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.

12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.

Oil Filter

13. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill.

14. Reinstall the dipstick.


16. Start the engine. Allow it to idle for one to two minutes.

17. Stop the engine.

18. Check for leaks.

19. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

20. Dispose of used filter and oil properly.

75

MAINTENANCE

Transmission Oil

POLARIS recommends the use of POLARIS Synthetic SPORTSMAN

XP Transmission Fluid for this transmission. See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the transmission oil at the intervals outlined in the Periodic

Maintenance Chart beginning on page 68. See page 125 for the part numbers of POLARIS products.

Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the vehicle behind the footwell.

The drain plug is located on the bottom left side of the gearcase.

Fill

Level

Oil Check

1. Remove the footwell (see page 89).

2. Remove the fill plug. Check the oil level.

Drain Plug

3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to specification.

5. Reinstall the footwell.

Fill Plug

Oil Change

1. Remove the footwell.

2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Remove the fill plug. Add the proper amount of the recommended oil.


6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

76

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 68.

See page 125 for the part numbers of POLARIS products.

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 for service.

Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. See below for capacity.

The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

Fill

Level

Fluid Check

1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level.

2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.

Drain Plug


Fill

Plug

Fluid Change

1. Position the vehicle on a level surface. Remove the fill plug.

2. Place a drain pan under the demand drive unit. Remove the drain plug. Allow the fluid to drain completely.

3. Clean and reinstall the drain plug. Torque to specification.

4. Add the proper amount of the recommended fluid.


6. Check for leaks. Dispose of used fluid properly.

77

MAINTENANCE

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two fluid levels that must be maintained (demand drive fluid and ADC fluid). See page 77 for demand drive fluid maintenance.

Check and change the ADC fluid level at the intervals outlined in the

Periodic Maintenance Chart beginning on page 68.

NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primary operation in ADC mode.

We recommend the use of POLARIS Demand Drive Plus Fluid. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 125 for the part numbers of POLARIS products.

NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.

1. Remove the front rack.

2. View the fluid level in the reservoir.

ADC Fluid Reservoir

3. If the level is below the minimum mark, remove the cap and add the recommended fluid.

4. Reinstall the cap.

5. Reinstall the front rack.

78

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves

(one on each side of the differential).

Bleeder

Screw

Cap

Bleeder

Valve

Screw

3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir. Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.

4. Fill the reservoir to the maximum line with fresh recommended fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the screws (turn counter-clockwise) and allow fluid and trapped air to flow from the fitting. Tighten the screw when clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. Add fresh recommended fluid to the reservoir until the level is between the minimum and maximum marks. Make sure the reservoir is free of debris.

9. Reinstall the cap securely. Clean up any drips or spills.

79

MAINTENANCE

Rear Gearcase Oil

See the table on page 72 for fluid recommendations, capacities and plug torques. Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 68. See page 125 for the part numbers of POLARIS products.

The fill plug is located on the rear of the gearcase. The drain plug is located on the bottom of the gearcase.

Fill

Level Maintain the fluid level at the bottom of the fill hole threads.

Do not overfill.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug.

Check the oil level.

Fill Plug

3. Add the recommended oil as needed to bring the level to the bottom of the fill hole threads. Do not overfill .


Drain Plug

80

MAINTENANCE

Rear Gearcase Oil

Oil Change


2. Place a drain pan under the drain hole.

3. Remove the drain plug. Allow the oil to drain completely.

4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.

5. Remove the fill plug. Add the proper amount of the recommended oil. Do not overfill .


7. Check for leaks.

8. Dispose of used oil properly.

81

MAINTENANCE

Power Steering Unit

If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas thoroughly.

Clean often

Cooling System

The engine coolant level is controlled by the recovery system. Recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.

As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

POLARIS recommends the use of POLARIS Premium 60/40 antifreeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page

125 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

82

MAINTENANCE

Cooling System

Recovery Bottle Coolant

The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage compartment.

1. View the fluid level in the bottle.

2. If the level is low, remove the front rack.

3. Remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

4. Reinstall the cap.


Maximum

Mark

Minimum

Mark

Recovery

Bottle Cap

83

MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,

POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.


2. Remove the pressure cap.

3. Using a funnel, slowly add coolant through the radiator filler neck.

4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.


Radiator

Cap

84

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride.

Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

Operating the vehicle with a spongy brake can result in loss of braking, which could cause an accident. Never operate the vehicle with spongy-feeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 125 for the part numbers of POLARIS products.

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level.

Do not overfill.

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

85

MAINTENANCE

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a level surface. Make sure the handlebars are straight.

2. View the fluid level through the indicator window (eye) on the top of the master cylinder.

Tip: The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

3. If the fluid level is low, remove the cover screws and add fluid to the fill line. Do not overfill.

Master

Cylinder

4. Reinstall the cover. Torque screws to 7 in. lbs. (.8 Nm).

Foot Brake

Brake Fluid Reservoir

The foot brake fluid reservoir is located under the front rack. The brake fluid reservoir cap is black.

NOTICE: Do not use ADC fluid in the brake fluid reservoir. ADC fluid will damage the rubber components of the brake system.

Indicator

Window

Full

Low

86

MAINTENANCE

Brake Inspections

The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Perform the following checks to keep the brake systems in good operating condition. Check more often if brakes are used heavily under normal operation.

1. Always keep brake fluid at an adequate level. See page 86.

2. Check the brake systems regularly for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness. Replace the pads when the friction material is worn to 1 mm.

1 mm

5. Check the security and surface condition of the disc.

87

MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 0" to 1/8" (0-3 mm) toe out.

Severe injury or death can result from improper toe alignment and adjustment.

Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.


2. Place the handlebars in a straight-ahead position.

3. Tie a length of string between two stands as shown in the illustration.

Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straightedge instead of string.

Stand

String

2

4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim.

1

The rear measurement should be 1.5 mm more than the front measurement on each side of the vehicle to obtain the recommended 0" to 1/8" (0-3 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.

88

MAINTENANCE

Steering Assembly

The steering assembly should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Seat Removal

1. Grasp one side of the seat near the rear edge.

2. Pull upward abruptly to disengage the under-seat fasteners.

3. Remove the seat.

Side Panel/Footwell Removal

Remove the seat before removing a side panel. Remove the screws and rivets securing the side panel or footwell (see illustration).

Plastic Rivet

Torx Head

Screw

Plastic Rivet

Hex Head Screw

Plastic Rivet

89

MAINTENANCE

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 126 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.

1/8" (3 mm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized

POLARIS dealer.

Wheel Removal

1. Stop the engine.


3. Loosen the wheel nuts slightly.

Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer.

4. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

5. Remove the wheel nuts.

6. Remove the wheel.

90

MAINTENANCE

Tires

Wheel Installation


2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped).

3. Install the wheel nuts and finger-tighten them.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.

Cast Aluminum

75 ft. lbs.

(102 Nm)

45 ft. lbs.

(61 Nm)

Steel

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loosened for maintenance service.

Wheel Type

Aluminum

Steel

Nut Type

Lug Nut

Lug Nut

Nut Torque

75 ft. lbs. (102 Nm)

45 ft. lbs. (61 Nm)

91

MAINTENANCE

Air Filter

1. Remove the seat.

2. Remove the air box cover screws, and remove the air box cover.

3. Remove the filter.

4. Remove the fabric type prefilter from the main filter.

Wash the pre-filter in soapy water, then rinse and let dry.

5. Reinstall the pre-filter over the main filter. Install a new main filter if needed.

6. Reinstall the filter into the air box.

7. Reinstall the air box cover and the seat.

Pre-Filter

Main

Filter

Screws

92

MAINTENANCE

Fuse Replacement

If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.


2. Remove the fuse box cover.

3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.

4. Reinstall the fuse box cover.


Fuse Box

550 850

93

MAINTENANCE

Lights

Headlight Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m from a wall.


3. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.

7.6 m

X X

5 cm

NOTE: Include rider weight on the seat when measuring.

4. Start the engine.Turn the headlight switch to high beam.

5. Observe the headlight aim on the wall. The most intense part of the headlight beam should be

5 cm below the mark on the wall.

6. Tighten or loosen the three (3) headlight screws to adjust the beam upward or downward or to the left or right.

Screws

94

MAINTENANCE

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do not touch the lamp with bare fingers.

Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. Hold the plastic part of the lamp.


2. Open the front rack cover.

3. Remove the plug at the back of the headlight.

4. Pull the harness plug to disconnect it from the back of the headlight.

5.

Position light: Rotate the socket to remove it. Go to step 6.

Headlamp: Reach under the bumper and remove the rubber cover from the back of the headlight. Turn the collar counterclockwise and carefully remove the collar and socket.

6. Remove the lamp. Apply dielectric grease to the socket and install a new lamp.

7. Reverse all steps to reassemble the headlight.

Position Light

Collar

Socket

Headlamp

95

MAINTENANCE

Lights

Front Turn Signal Replacement

If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly.

Rear Turn Signal Lamp Replacement


2. Rotate the turn signal socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

96

MAINTENANCE

Lights

Taillight/Brakelight Lamp Replacement


PARK.

2. Rotate the taillight socket counterclockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp for proper operation.

6. Reinstall all components in reverse order.

97

MAINTENANCE

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment.

Throttle Cable Freeplay

1. Remove the three cover screws from the right handlebar control and remove the cover.

2. With the handlebars straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm.

If adjustment is needed:

1. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut.

2. Loosen the adjuster locknut.

3. Rotate the boot to turn the adjuster until 2-3 mm of freeplay is achieved between the stop pin and the throttle arm. While adjusting freeplay, flip the throttle lever back and forth repeatedly.

(continued on next page)

Arm Stop Pin

Cable

Adjuster

Boot

Lock

Nut

Throttle

Arm

2-3 mm Gap

Adjuster

98

MAINTENANCE

Throttle Cable Freeplay


5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle lever to ensure the idle speed settles.

6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer for service.

7. With the engine running, turn the handlebars fully to the left and right. Tap the throttle lever at each turn, verifying that idle RPM returns to the recommended setting. If idle speed increases, it may be necessary to increase the gap between the stop pin and throttle arm, but do not exceed the recommended 2-3 mm gap.

8. When adjustments are complete, tighten the locknut.

9. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.

10. Ensure the control cover seal is in place, then reinstall the cover and screws.

99

MAINTENANCE

Camber and Caster

The camber and caster are non-adjustable.

Front and Rear Springs

The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Accessory springs are available through your

POLARIS dealer.

Adjuster

Handlebars

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

4. Torque the front two bolts to

10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.

5.

Handlebar

Bolts

100

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 126 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.

Plug Condition

New Spark Plug

Previously Installed

Spark Plug

Torque Specification

550

9-11 ft. lbs.

(12-15 Nm)

17-20 ft. lbs.

(23-27 Nm)

850

18-20 ft. lbs.

(24-27 Nm)

18-20 ft. lbs.

(24-27 Nm)

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plugs for correct color. See page 102.

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 counterclockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to specification.

101

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

The tip should not be flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended oil or incorrect throttle body adjustments.

102

MAINTENANCE

Vehicle Immersion

If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the footrests.

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter.

3. Remove the spark plugs.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs. Reinstall the plugs or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying procedure.

7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.

8. If water has been ingested into the PVT, follow the procedure on page 107 for drying out the PVT.

103

MAINTENANCE

Spark Arrestor

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging.

Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler.

1. Remove the arrestor cleanout plug from the bottom of the muffler.


PARK.

3. Start the engine.

4. Quickly squeeze and release the throttle lever several times to purge carbon from the system.

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet(s). Wear protective gloves.

Clean-Out Plug

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating step 4.

7. If particles are still suspected to be in the muffler, elevate the rear of the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Place the transmission in PARK. Repeat steps 4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor clean-out plug and remove the exhaust outlet cover or plug.

104

MAINTENANCE

PVT System

Failure to comply with the instructions in this warning can result in severe injury or death.

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as outlined in the owner's manual.

• This PVT system is intended for use on POLARIS products only. Do not install it in any other product.

• Always make sure the PVT housing is securely in place during operation.

105

MAINTENANCE

PVT System

The basic operation of the POLARIS PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.

The approximate gear ratio difference between high and low range is

1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1600 - 1800 RPM. However, in high range at 3 MPH (5 km/h), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.

The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).

106

MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

Operating at speeds less than 7 MPH (11 km/h)

Towing heavy loads

Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 7 MPH (11 km/h)

Range to Use

Low

Low

Low

High

PVT Drying

There may be some instances when water is accidently ingested into the

PVT system. Use the following instructions to dry it out before operating.


2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.

3. Start the engine. Place the transmission in PARK.

4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

5. Allow the engine RPM to settle to idle speed, then shift the transmission to the lowest available range.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

107

MAINTENANCE

Battery

Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing.

Antidote:

External : Flush with water.

Internal : Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately.

Eyes : Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your vehicle may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery.

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. Be careful not to allow cleaning solution or tap water into a conventional battery.

108

MAINTENANCE

Battery

Battery Removal

1. Remove the seat.

2. Disconnect the black (negative) battery cable first.

3. Disconnect the red (positive) battery cable last.

4. Disconnect the battery hold-down strap.

5. On conventional batteries, remove the battery vent tube.

6. Lift the battery out of the vehicle. Be careful not to tip a conventional battery sideways, which could spill electrolyte.

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.

109

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 112 before installing the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease or petroleum jelly.

5. Secure the battery hold-down strap.

6. Connect and tighten the red (positive) cable first.

7. Connect and tighten the black (negative) cable last.

8. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.

9. Install the seat.

110

MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge.

POLARIS recommends maintaining battery charge by using a

POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 125 for the part numbers of POLARIS products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks.

Add only distilled water. Tap water contains minerals that are harmful to a battery.

Lower

Mark

Upper

Mark

111

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 109.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 110. Make sure the positive terminal polarity is properly connected.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register

12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging.

112

MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of charging.

State of

Charge

100%

75%-100%

50%-75%

25%-50%

0%-25%

Voltage Action

Charge Time

(Using constant current charger @ standard amps specified on top of battery)

None required 12.8-13.0 volts

12.5-12.8 volts

12.0-12.5 volts

11.5-12.0 volts

None, check at 3 mos. from date of manufacture

May need slight charge, if no charge given, check in 3 months

Needs charge

Needs charge

11.5 volts or less Needs charge with desulfating charger

3-6 hours

5-11 hours

At least 13 hours, verify state of charge

At least 20 hours

113

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

114

MAINTENANCE


Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items:

• 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.

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

115

MAINTENANCE


Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years.

Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each polished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT grade) to remove it. Gently rub the affected areas with the steel wool until the corrosion has been removed. Clean and polish the wheel as outlined above.

116

MAINTENANCE


Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and then clean the vehicle as recommended.

See page 114.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel

Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 74.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

117

MAINTENANCE


Storage Tips

Fluid Levels

Inspect the following fluid levels. Change fluids as recommended in the

Periodic Maintenance Chart beginning on page 68.

• Demand drive unit (front gearcase)

• ADC fluid (ADC models) (change every two years)

• Rear gearcase

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength)

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean, following the instructions on the container. Run the engine for several minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear 1/4" hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.

3. Reinstall the spark plugs. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs.

5. Turn the engine over several times using electric start. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

6. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.

118

MAINTENANCE


Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 68.

Battery Maintenance

Remove the battery and recharge it as outlined on page 112. Store the battery in a cool, dry place.

Storage Area/Covers

Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

Accessories

Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your vehicle. Always install accessories that are approved by POLARIS for use on this vehicle.

119

MAINTENANCE

Transporting the Vehicle

1. Stop the engine.


3. Secure the fuel cap, oil cap and seat.

4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front Aarm bolt pockets, racks or handlebars.

5. Remove the key to prevent loss during transporting.

120

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall trailer in high range

Starting out going up a steep incline

Driving at low RPM or ground speed (3-7 MPH)

Insufficient warm-up at low ambient temperatures

Use low range during loading.

Use low range or turn around using the K-turn (see page

56).

Drive at a higher speed or use low range more frequently.

See page 107.

Warm the engine at least 5 minutes. With the transmission in neutral, advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The belt will become more flexible and prevent belt burning.

Use the throttle quickly and effectively.

Slow/easy clutch engagement

Towing/pushing at low

RPM/low ground speed

Utility use/plowing

Stuck in mud or snow

Use low range only.

Use low range only.

Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control and vehicle overturn.

Climbing over large objects from a stopped position

Wrong or missing belt

Improper break-in

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch.

WARNING!

Excessive throttle may cause loss of control and vehicle overturn.

Belt slippage from water or snow ingestion into the

PVT system

Clutch malfunction

Dry out the PVT. See page 107. Inspect clutch seals for damage if repeated leaking occurs.

See your POLARIS dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.

Slippage from failure to warm up belt

Always warm up the belt by operating below 30 mph for one mile (5 miles or more when temperature is below freezing).

Install the recommended belt.

Always break in a new belt and/or clutch. See page 43.

121

TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Low battery voltage

Loose battery connections

Loose solenoid connections

Solution

Recharge the battery to 12.8 VDC

Check all connections and tighten


Engine Turns Over, Fails to Start

Out of fuel

Possible Cause

Clogged fuel filter

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plugs

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Mechanical failure

Engine Backfires

Possible Cause

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Mechanical failure

Loose ignition connections

Water present in fuel

Solution

Refuel, cycle key to ON position three times for 5 seconds each, then start

See your dealer

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your POLARIS dealer


See your dealer

Solution

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs


See your dealer

See your dealer

See your dealer



122

TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Poor quality or low octane fuel

Incorrect ignition timing


Solution

Replace with recommended fuel

See your dealer


Engine Runs Irregularly, Stalls or Misfires

Possible Cause


Worn or defective spark plug wires



Water present in fuel

Low battery voltage

Kinked or plugged fuel tank vent line

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Possible Lean Fuel Cause

Low or contaminated fuel

Kinked or plugged fuel tank vent line

Low octane fuel

Clogged fuel filter

Incorrect fuel

Possible Rich Fuel Cause

Fuel is very high octane

Stopping/starting without adequate warm-up

Incorrect fuel

Clogged air filter

Solution

Inspect, clean and/or replace spark plugs

See your dealer



Replace with new fuel

Recharge battery to 12.8 VDC

Inspect and replace


Inspect and clean or replace

See your dealer

See your dealer

See your dealer

Solution

Add or change fuel, clean the fuel system

Inspect and replace


See your dealer


Solution

Replace with lower octane fuel

Allow engine to warm up before operating and/or stopping



123

TROUBLESHOOTING

Engine Stops or Loses Power

Out of fuel

Possible Cause

Kinked or plugged fuel vent line

Water is present in fuel


Worn or defective spark plug wires



Low battery voltage

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

Solution

Refuel, cycle key to ON position three times for 5 seconds each, then start

Inspect and replace

Replace with new fuel

Inspect, clean and/or replace spark plug

See your dealer

Set gap to specs or replace plug





See your dealer

See your dealer

See your dealer

Clean radiator screen and core, clean engine exterior, see your dealer

Engine Overheating

Possible Cause

Debris lodged in screen

Plugged Radiator

Solution

Clean the screen.

Use a garden hose to flush any debris from the radiator fins. NOTE: High pressure washers can deform the radiator fins and reduce cooling efficiency.

124

POLARIS PRODUCTS

Part

Number

Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol)

2876244 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt./.95 l)

2876245 PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL PLUS Transmission Fluid (qt./.95 l)

2878069 AGL PLUS Transmission Fluid (gal./3.8 l)

2877922 Demand Drive Plus Fluid (qt./.95 l)

2877923 Demand Drive Plus Fluid (gal./3.8 l)

2871653 Premium ATV Angle Drive Fluid (8 oz./237 ml)

2872276 Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

2870465 Pump for Gallon (3.8 l) Jug

Coolant

2871323 60/40 Coolant (gal./3.8 l)

2871534 60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, Premium All Season

2871322 Premium All Season Grease (3 oz./89 ml cartridge)

2871423 Premium All Season Grease (14 oz./414 ml cartridge)

2871460 Starter Drive Grease

2871515 Premium U-Joint Lube (3 oz./89 ml cartridge)

2871551 Premium U-Joint Lube (14 oz./414 ml cartridge)

2871329 Dielectric Grease (Nyogel TM )

Additives / Miscellaneous

2871326 Carbon Clean Plus

2870652 Fuel Stabilizer

2872189 DOT 4 Brake Fluid

2871956 Loctite TM 565 Thread Sealant

2859044 POLARIS Battery Tender TM Charger

125

SPECIFICATIONS

SPORTSMAN Forest 550

Maximum Weight Load Capacity 575 lbs. (261 kg)

Dry Weight 342 kg +/- 7 % , based on configuration

Fuel Capacity

Engine Oil Capacity

4.5 gal. (17 l)

2 qts. (1.9 l)

Coolant Capacity

Rear Gearcase Oil Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

2 qts. (1.9 l)

7.1 oz. (210 ml)

9.3 oz. (275 ml)

32 oz. (950 ml)

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity 240 lbs. (109 kg)

Unbraked Trailer Towing

Capacity*

1786 lbs. (810 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

83.25 in. (211 cm)

47.6 in. (121 cm)

50.75 in. (129 cm)

53 in. (134.6 cm)

Ground Clearance

Minimum Turning Radius

Engine

Displacement

Engine Power

Bore x Stroke

Alternator Output

Compression Ratio

Starting System

Ignition System

Idle RPM

Ignition Timing

Spark Plug / Gap

Lubrication System

Seat

Steering System

Transmission Power System

Driving System Type

Front Suspension

Rear Suspension

11.6 in. (29.5 cm)

84 in. (213 cm) unloaded

ES550PLE (Low Torque Capacity)

549.7 cc

30 kW

96.6 x 75

490w @ 1350 RPM/Peak 630w

9.6:1

Electric

Electronic Fuel Injection

1650 +/- 100 RPM

13 +/- 3 BTDC @ 1350 RPM, Engine warm

NGK BKR6E / .035 in. (0.9 mm)

Wet Sump

Single Seat, length 650 mm

Akerman Principle, with handlebar controls

Shaft drive on all wheels

Automatic PVT (POLARIS Variable Transmission)

Dual a-arm with 9.2" (23 cm) travel

Progressive rate with 10.2" (26 cm) travel

* Based on EU Directive 76/432/EC

126

SPECIFICATIONS

Tires Type Rear

Brakes, Front/Rear

Brakes, Auxiliary

Parking Brake

Hitch

Winch

Headlight

Taillights

Brake Light

Instrument Cluster


Transmission and Gears

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Drive Ratio, Rear

Tires Type Front

High/Low/Neutral/Reverse/Parking

5.034:1

4.508:1

2.693:1

3.818:1

3.7:1

Off Road Style, Deep Tread Design, size 26x8-14

AT / 7 psi (48.3 kPa) Pressure

Off Road Style, Deep Tread Design, size 26x10-

14 AT / 5 psi (34.5 kPa) Pressure

Single-Control handlebar hydraulic disc on all wheels

Foot-Activated Hydraulic Disc on all wheels

Hydraulic lock, all wheel, Mechanical on Gearbox

Rear mounting for attachment of coupling devices

Front permanent Installed winch with 2500 lbs,

1,125 kg Capacity

2 dual beam on bumper (55/60 watt)

7 watts

27 watts

Digital LCD/LED

Clutching

Altitude Shift

Weight

Drive Clutch

Spring

Helix*

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

23-58

PN 5632218

23-54

PN 5632219

Red/Black

PN 7043500

Red/Black

PN 7043500

*EBS models require no helix/spring adjustment

Driven

Clutch

Spring

Red/White

PN 3235621

Red/White

PN 3235621

52



BA-500

PN 3234620

52



BA-500

PN 3234620

127

SPECIFICATIONS


Maximum Weight Load Capacity 575 lbs. (261 kg)

Dry Weight 360 kg +/- 7 % , based on configuration

Fuel Capacity

Engine Oil Capacity

4.5 gal. (17 l)

2 qts. (1.9 l)

Coolant Capacity

Rear Gearcase Oil Capacity

Demand Drive Fluid Capacity

Transmission Oil Capacity

2 qts. (1.9 l)

7.1 oz. (210 ml)

9.3 oz. (275 ml)

32 oz. (950 ml)

Front Rack/Storage Box Capacity 120 lbs. (54 kg)

Rear Rack Capacity 240 lbs. (109 kg)

Unbraked Trailer Towing

Capacity*

1914 lbs. (868 kg)

Overall Length

Overall Width

Overall Height

Wheelbase

83.25 in. (211 cm)

47.6 in. (121 cm)

50.75 in. (129 cm)

53 in. (134.6 cm)

Ground Clearance

Minimum Turning Radius

Engine

Displacement

Engine Power

Bore x Stroke

Alternator Output

Compression Ratio

Starting System

Ignition System

Idle RPM

Ignition Timing

Spark Plug Type / Gap

Lubrication System

Seat

Steering System

Transmission Power System

Driving System Type

Front Suspension

Rear Suspension

11.6 in. (29.5 cm)

84 in. (213 cm) unloaded

EHO850LE (Low Torque Capacity)

850 cc

51.5 kW

87 x 71.5

475w @1200 RPM/Peak 575w

11:1

Electric

Electronic Fuel Injection

1200 +/- 100 RPM

6 +/- 5 BTDC @ 1200 RPM, Engine warm

Champion REA6MC / .035 in. (0.9 mm)

Wet Sump

Single Seat, length 650 mm

Akerman Principle, with handlebar controls

Shaft drive on all wheels

Automatic PVT (POLARIS Variable Transmission)

Dual a-arm with 9.2" (23 cm) travel

Progressive rate with 10.2" (26 cm) travel

* Based on EU Directive 76/432/EC

128

SPECIFICATIONS

Tires Type Rear

Brakes, Front/Rear

Brakes, Auxiliary

Parking Brake

Hitch

Winch

Headlight

Taillights

Brake Light

Instrument Cluster


Transmission and Gears

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Drive Ratio, Rear

Tires Type Front

High/Low/Neutral/Reverse/Parking

5.034:1

4.508:1

2.367:1

3.818:1

3.7:1

Off Road Style, Deep Tread Design, size 26x8-14

AT / 7 psi (48.3 kPa) Pressure

Off Road Style, Deep Tread Design, size 26x10-

14 AT / 5 psi (34.5 kPa) Pressure

Single-Control handlebar hydraulic disc on all wheels

Foot-Activated Hydraulic Disc on all wheels

Hydraulic lock, all wheel, Mechanical on Gearbox

Rear mounting for attachment of coupling devices

Front permanent Installed winch with 2500 lbs,

1,125 kg Capacity

2 Hi/Lo beam on bumper (37.5 watt)

7 watts

27 watts

Digital LCD/LED

Clutching

Altitude

Meters

(Feet)

0-1800

(0-6000)

1800-3700

(6000-12000)

Shift

Weight

Drive Clutch

Spring

24-63

PN5632215

24-60

PN 5632216

Red/White

PN 7043349

Red/White

PN 7043349

Driven

Clutch

Spring

Red/White

PN 3235621

Red/White

PN 3235621

Helix*

52



BA-500

PN 3234620

52



BA-500

PN 3234620

*EBS models require no helix/spring adjustment

129

DECLARATION OF CONFORMITY

POLARIS Industries Inc.,

2100 Hwy 55, Medina, MN 55340 U.S.A.

Telephone 763-542-0500

We, POLARIS Industries Inc., declare that the vehicles listed below conform to the essential health and safety requirements applicable to off-road all-terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES

2006/42/EC as amended (Machinery Directive)

2004/108/EC as amended (EMC Directive)

TEST / EVALUATION METHODS

EN 1050 hazard analysis prEN 15997 driver-perceived noise level prEN 15997 vibration

CISPR 12:2009

CAN/CSA-C108.4-M92

EN 55012:2007

EN 61000-6-2:2005

PRODUCT IDENTIFICATION

VEHICLE SERIES

___MH50__

___ZN55__, ___ZX55__

___ZN85__, ___ZX85__

TRADE NAME

SPORTSMAN FOREST 500



European Community Person

Authorized to Compile the Technical File:

2011

2011

2011

MODEL YEARS

Ross Clifford, General Manager

POLARIS Britain Ltd

Forge Mills Park, Station Road

Coleshill, Warwickshire B46 1HT

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

130

WARRANTY

LIMITED WARRANTY

POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a TWO YEAR

LIMITED WARRANTY on all components of the POLARIS vehicle against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase. This warranty is transferable to another consumer during the warranty period through a POLARIS dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days. 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 the warranty entitlement. 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 vehcile 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.

131

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle that has been altered structurally, modified, neglected, improperly maintained, used for racing, or used for purposes other than for which it was manufactured, or for any damages which occur during trailer transit or as a result of unauthorized service or the use of unauthorized parts. In addition, this warranty does not cover physical damage to paint or finish, stress cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, components or the vehicle due to fire, explosions or any other cause beyond

POLARIS' control.

Warranty does not apply to 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

• Finished and unfinished surfaces

• Carburetor/Throttle body components

• Engine components

• Drive belts

• Hydraulic components

• Circuit breakers/Fuses

• Electronic components

Warranty applies to the product only and does not allow for coverage of personal loss.

Some items are considered "consumable," meaning they are considered part of normal maintenance or part of completing an effective repair. The following items are excluded from warranty coverage in the event of a warranty claim:

• Spark Plugs

• Filters

• Fuel

• Sealants

• Hotel fees

• Towing charges

• Mileage

• Rentals/Loss of product use

• Lubricants such as oil, grease, etc.

• Batteries (unless defective)

• Cosmetic damage/repair

• Coolants

• Meals

• Shipping/ handling fees

• Product pick-up/delivery

• Loss of vacation/personal time

132

WARRANTY

LIMITATIONS OF WARRANTIES AND REMEDIES

This warranty also excludes 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; failure due to snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket components resulting in failure; unauthorized repairs; repairs made after the warranty period expires or by an unauthorized repair center; use of the product in competition or for commercial purposes. Warranty will not apply to any product which has been damaged by abuse, accident, fire or any other casualty not determined a defect of materials or workmanship.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that are not compatible with the vehicle. The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive option, repair or replacement of any defective materials, or 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 WAR-

RANTY 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 PUR-

POSE. Some states do not permit the exclusion or limitation of incidental or consequential damages or implied warranties, so the above limitations or exclusions may not apply to you if inconsistent with controlling state law.

133

WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE TWO

YEAR WARRANTY PERIOD. POLARIS FURTHER 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 to you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a POLARIS dealer authorized to repair POLARIS vehicles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (THE COST OF TRANS-

PORTATION 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.

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.

If any of the above terms are void because of state or federal law, all other warranty terms will remain in effect.

134

MAINTENANCE LOG

Present this section of your manual to your dealer each time your vehicle is serviced.

This will provide you and future owners with an accurate log of maintenance and services performed.

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

135

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS


136

MAINTENANCE LOG

DATE MILES (KM)

OR HOURS


137

INDEX

0-9

4X4 Switch . . . . . . . . . . . . . . . . 20, 28

A

Access, Front Compartment . . . . . . 27

Accessories . . . . . . . . . . . . . . . . . . 119

Active Descent Control Fluid . . . 78-79

Active Descent Control System. . . . 30

ADC System . . . . . . . . . . . . . . . . . . 30

Age Restrictions. . . . . . . . . . . . . . . . . 6

Air Filter . . . . . . . . . . . . . . . . . . . . . 92

All Wheel Drive System . . . . . . . 28-29

B

Battery . . . . . . . . . . . . . . . . . . 108-113

Charging (Conventional) . . . . 112

Charging (Sealed) . . . . . . . . . 113

Charging (Sealed) . . . . . . . . . 112

Fluid (Conventional) . . . . . . . 111

Installation . . . . . . . . . . . . . . . 110

Removal. . . . . . . . . . . . . . . . . 109

Storage . . . . . . . . . . . . . . . . . . 111

Belt Life . . . . . . . . . . . . . . . . . . . . . . 25

Boots . . . . . . . . . . . . . . . . . . . . . . . . 15

Brake Fluid . . . . . . . . . . . . . . . . . 85-86

Brake Inspections. . . . . . . . . . . . . . . 87

Brake Lever . . . . . . . . . . . . . . . . . . . 23

Brake, Foot . . . . . . . . . . . . . . . . 23, 86

Brake, Hand Lever. . . . . . . . . . . . . . 86

Brake, Parking . . . . . . . . . . . . . . . . . 24

Brakelight . . . . . . . . . . . . . . . . . . . . 97

Brakes . . . . . . . . . . . . . . . . . . . . . 23-24

Break-In Period . . . . . . . . . . . . . . 42-43

C

Camber Adjustment . . . . . . . . . . . . 100

Cargo . . . . . . . . . . . . . . . . . . . . . . 58-59

Caster Adjustment . . . . . . . . . . . . . 100

Chrome Wheel Care . . . . . . . . . . . 116

Cleaning and Storage. . . . . . . . 114-119

Clothing . . . . . . . . . . . . . . . . . . . . . . 15

Clutching

550 XP . . . . . . . . . . . . . . . . . . 127

850 XP . . . . . . . . . . . . . . . . . . 129

Cold Weather Operation . . . . . . . . . 45

Coolant Bottle . . . . . . . . . . . . . . . . . 83

C

Coolant, Radiator. . . . . . . . . . . . . . . . 84

Cooling System . . . . . . . . . . . . . . 82-84

Corrosion Removal, Chrome. . . . . . 116

D

Demand Drive Fluid . . . . . . . . . . . . . 77

Diagnostic Codes

550 XP EPS . . . . . . . . . . . . . 38-39

850 XP EPS . . . . . . . . . . . . . 40-41

Disengaging Active Descent Control 30

Display, Standard/Metric. . . . . . . . . . 35

Drive Belt Wear/Burn . . . . . . . . . . . 121

Drivetrain Break-In . . . . . . . . . . . . . . 43

Driving Downhill. . . . . . . . . . . . . . . . 55

Driving in Reverse. . . . . . . . . . . . . . . 51

Driving on a Sidehill . . . . . . . . . . . . . 54

Driving on Slippery Surfaces . . . . . . 48

Driving Over Obstacles . . . . . . . . . . . 50

Driving Procedures . . . . . . . . . . . . . . 46

Driving Through Water . . . . . . . . . . . 49

Driving Uphill . . . . . . . . . . . . . . . 52-53

E

Electromagnetic Interference. . . . . . . 67

Electronic Power Steering . . . . . . . . . 25

Electronic Throttle Control . . . . . . . . 22

Engaging 4X4 . . . . . . . . . . . . . . . . . . 29

Engaging Active Descent Control . . . 30

Engine Break-In. . . . . . . . . . . . . . . . . 43

Engine Fogging . . . . . . . . . . . . . . . . 118

Engine Oil . . . . . . . . . . . . . . . . . . 73-75

EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 25

EPS Warning Indicator . . . . . . . . . . . 33

Equipment Modifications . . . . . . . . . . 6

Exhaust Emission Control System . . 67

Eye Protection . . . . . . . . . . . . . . . . . . 15

F

Fluid

ADC. . . . . . . . . . . . . . . . . . . 78-79

Brake . . . . . . . . . . . . . . . . . . 85-86

Demand Drive . . . . . . . . . . . . . . 77

Engine . . . . . . . . . . . . . . . . . 73-75

Gearcase, Rear . . . . . . . . . . . 80-81

Transmission . . . . . . . . . . . . . . . 76

138

F

Fluid Change

ADC . . . . . . . . . . . . . . . . . . . . . 79

Demand Drive. . . . . . . . . . . . . . 77

Engine . . . . . . . . . . . . . . . . . 74-75

Rear Gearcase . . . . . . . . . . . . . . 81

Transmission. . . . . . . . . . . . . . . 76

Foot Brake, Auxiliary . . . . . . . . . . . . 23

Footwell Removal. . . . . . . . . . . . . . . 89

Front Compartment. . . . . . . . . . . . . . 27

Front Gearcase (Demand Drive). . . . 77

Front Rack/Compartment . . . . . . . . . 27

Fuel Tank Cap. . . . . . . . . . . . . . . . . . 26

Fuse Replacement . . . . . . . . . . . . . . . 93

G

Gear Selector. . . . . . . . . . . . . . . . . . . 25

Gearcase Oil, Rear . . . . . . . . . . . 80-81

Gloves . . . . . . . . . . . . . . . . . . . . . . . . 15

H

Hand Brake . . . . . . . . . . . . . . . . . . . . 86

Handlebar Adjustment . . . . . . . . . . 100

Hauling Cargo. . . . . . . . . . . . . . . 58-59

Hazard Warning Switch . . . . . . . . . . 21

Headlight Lamp . . . . . . . . . . . . . . . . 95

Headlight Switch. . . . . . . . . . . . . . . . 21

Helmet. . . . . . . . . . . . . . . . . . . . . . . . 14

High Beam Switch, Momentary . . . . 20

High Range Use . . . . . . . . . . . . . . . 107

Horn Switch . . . . . . . . . . . . . . . . . . . 21

I

Idle RPM Adjustment . . . . . . . . . . . . 98

Immersion . . . . . . . . . . . . . . . . . . . . 103

Instrument Cluster. . . . . . . . . . . . 31-41

K

Key Switch . . . . . . . . . . . . . . . . . . . . 21

K-Turn . . . . . . . . . . . . . . . . . . . . 56-57

INDEX

L

Light Switch . . . . . . . . . . . . . . . . . . . 20

Lights

Headlight Beam Adjustment. . . 94

Headlight Lamp . . . . . . . . . . . . 95

Momentary High Beam Switch 20

Position Light Lamp . . . . . . . . . 95

Front Turn Signal . . . . . . . . . . . 96

Rear Turn Signal. . . . . . . . . . . . 96

Taillight/Brakelight/Worklight . 97

Low Beam Adjustment . . . . . . . . . . . 94

Low Range Use. . . . . . . . . . . . . . . . 107

Lubrication Guide. . . . . . . . . . . . . . . 72

M

Maintenance Chart . . . . . . . . . . . 68-71

Metric/Standard Display. . . . . . . . . . 35

Mirrors . . . . . . . . . . . . . . . . . . . . . . . 22

Mode Switch. . . . . . . . . . . . . . . . . . . 20

Modifications . . . . . . . . . . . . . . . . . . . 6

N

Noise Emission Control System . . . . 67

O

Oil

Engine . . . . . . . . . . . . . . . . . 73-75

Rear Gearcase . . . . . . . . . . . 80-81

Transmission. . . . . . . . . . . . . . . 76

Oil and Filter Change . . . . . . . . . 74-75

Oil Level, Engine . . . . . . . . . . . . . . . 73

Oil Recommendations . . . . . . . . . . . 73

Override Switch . . . . . . . . . . . . . . . . 20

P

Parking Brake . . . . . . . . . . . . . . . . . . 24

Parking on an Incline . . . . . . . . . . . . 60

Periodic Maintenance Chart . . . . 68-71

Polaris Product List. . . . . . . . . . . . . 125

Polishing the Vehicle . . . . . . . . . . . 115

Position Light Lamp . . . . . . . . . . . . . 95

Power Steering . . . . . . . . . . . . . . . . . 25

Power Steering Unit (Cleaning) . . . . 82

Pre-Ride Checklist . . . . . . . . . . . . . . 44

PVT Break-In . . . . . . . . . . . . . . . . . . 43

PVT Drying . . . . . . . . . . . . . . . . . . 107

PVT System . . . . . . . . . . . . . . 105-107

139

INDEX

R

Rack/Compartment, Front . . . . . . . . 27

Reverse Operation . . . . . . . . . . . . . . 51

Reverse Override Switch . . . . . . . . . 20

Rider Information Center. . . . . . . 32-41

Rider Safety . . . . . . . . . . . . . . . . . . 7-13

Riding Gear . . . . . . . . . . . . . . . . . 14-15

S

Safety Labels . . . . . . . . . . . . . . . . 16-19

Safety Training . . . . . . . . . . . . . . . . . 6

Severe Use . . . . . . . . . . . . . . . . . . . . 68

Side Panel Removal. . . . . . . . . . . . . 89

Sidehilling . . . . . . . . . . . . . . . . . . . . 54

Signal Words . . . . . . . . . . . . . . . . . . . 4

Spark Arrestor . . . . . . . . . . . . . . . . 104

Spark Arrestor Requirements . . . . . 67

Spark Plug Inspection . . . . . . . 101-102

Spark Plug Recommendations. . . . 101

Spark Plugs . . . . . . . . . . . . . . . 101-102

Spring Adjustment, Shock . . . . . . . 100

Standard/Metric Display . . . . . . . . . 35

Starting the Engine . . . . . . . . . . . . . 45

Steering Assembly . . . . . . . . . . . . . . 89

Steering Lock. . . . . . . . . . . . . . . . . . 26

Storage . . . . . . . . . . . . . . . . . . . 114-119

Storage Tips . . . . . . . . . . . . . . . 117-119

Switches. . . . . . . . . . . . . . . . . . . . 20-21

4X4 Switch . . . . . . . . . . . . 20, 28

Engine Stop Switch . . . . . . . . . 21

Hazard Warning. . . . . . . . . . . . 21

Headlight Switch . . . . . . . . . . . 21

Horn . . . . . . . . . . . . . . . . . . . . . 21

Main Key Switch . . . . . . . . . . . 21

Mode Switch . . . . . . . . . . . . . . 20

Momentary High Beam Switch 20

Reverse Override Switch . . . . . 20

Stop Switch . . . . . . . . . . . . . . . 21

Turn Signal . . . . . . . . . . . . . . . 21

Winch Switch . . . . . . . . . . . . . 20

T

Taillight . . . . . . . . . . . . . . . . . . . . . . . 97

Throttle Body Adjustment . . . . . . . . . 98

Throttle Cable Freeplay . . . . . . . . 98-99

Throttle Lever . . . . . . . . . . . . . . . . . . 22

Tire Tread Depth . . . . . . . . . . . . . . . . 90

Tires . . . . . . . . . . . . . . . . . . . . . . 90-91

Wheel Installation . . . . . . . . . . . 91

Wheel Nut Torque . . . . . . . . . . . 91

Wheel Removal . . . . . . . . . . . . . 90

Toe Alignment. . . . . . . . . . . . . . . . . . 88

Towing Loads . . . . . . . . . . . . . . . . . . 59

Training . . . . . . . . . . . . . . . . . . . . . . . . 6

Transmission Gear Selector. . . . . . . . 25

Transmission Oil . . . . . . . . . . . . . . . . 76

Transporting the Vehicle . . . . . . . . . 120

Turn Signal Lamp, Front . . . . . . . . . . 96

Turn Signal Lamp, Rear . . . . . . . . . . 96

Turn Signal Switch . . . . . . . . . . . . . . 21

Turning Around on a Hill . . . . . . 56-57

Turning the Vehicle . . . . . . . . . . . . . . 47

V

Vehicle Identification Numbers. . . . . . 5

Vehicle Immersion . . . . . . . . . . . . . 103

W

Warning Symbols . . . . . . . . . . . . . . . . 4

Washing the Vehicle . . . . . . . . 114-115

Wheel Hub Tightening . . . . . . . . . . . 90

Wheel Installation . . . . . . . . . . . . . . . 91

Wheel Nut Torque Specifications . . . 91

Wheel Removal . . . . . . . . . . . . . . . . . 90

Winch Cable Care . . . . . . . . . . . . . . . 62

Winch Operation . . . . . . . . . . . . . 65-66

Winch Preparation and Inspection. . . 63

Winch Rigging. . . . . . . . . . . . . . . . . . 64

Winch Safety Precautions . . . . . . . . . 61

140

No results