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PMS 419
Sportsman 550 X2
International
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.
The text is printed on 100% recycled with 40% post-consumer waste (PCW).
PMS 419
PASSENGER
UNDER
12
GB
D
I
FI
E
F
P
S
Before you operate or ride this vehicle, read the owner’s manual.
Lesen Sie die Bedienungsanleitung, bevor Sie dieses Fahrzeug bedienen oder fahren.
Antes de operar o conducir este vehículo, lea el
Manual del propietario.
Lire le Manuel d’utilisation avant d’utiliser ou de conduire ce véhicule.
Prima di usare o guidare il veícolo, leggere il
Manuale di istruzioni.
Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä tai ajamista.
Antes de utilizar ou andar neste veículo, leia o
Manual do proprietário.
Innan du hanterar eller kör detta fordon, läs
Handboken.
For your nearest Polaris dealer, visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340 USA
Part No. 9922826 Rev 01
Printed in USA
*9922826 *
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 ®
• Low emission vehicles (LEVs)
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.
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.
2011 Sportsman 550 X2 International Owner’s Manual
P/N 9922826
2
TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Features and Controls . . . . . . . . . . . . . . . . . . . 22
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Emission Control Systems . . . . . . . . . . . . . . . 70
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 127
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . 128
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.
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.
Engine Serial Number
Key
Number
####
VIN
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.
Never allow anyone under 16 years of age to operate this vehicle.
Never allow anyone under 12 years of age to ride as a passenger on this
2-up vehicle.
SAFETY
Restrictions
Towing is approved OFF-ROAD ONLY. Towing a trailer with this vehicle on public roads is prohibited. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.
Equipment Modifications
The warranty on your Polaris vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.
The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only
Polaris-approved accessories. Know their function and effect on the vehicle.
7
8
SAFETY
Rider Safety
Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.
Never operate this vehicle without proper instruction. Take a training course.
Beginners should receive training from a certified instructor.
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.
Never allow anyone under 12 years of age to ride as a passenger on this
2-up vehicle.
Never carry more than one passenger on this 2-up vehicle.
Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.
Rider Safety
Never consume alcohol or drugs before or while operating this vehicle.
Never operate at excessive speeds.
Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.
Never attempt jumps or other stunts.
Always inspect your vehicle before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual.
See page 49.
SAFETY
9
SAFETY
Rider Safety
Keep both hands on the handlebars.
Keep both feet on the footrests.
A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.
A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. Never allow a passenger to ride in the cargo box.
Always travel slowly when operating on unfamiliar terrain. Use extra caution.
Use caution when operating on rough, slippery or loose terrain.
10
SAFETY
Rider Safety
Always follow the procedures outlined in this manual for turning.
See page 53.
Never turn sharply at excessive speeds, which can lead to vehicle overturn.
If the vehicle has been involved in an accident, always have an authorized
POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.
Always follow the procedures outlined in this manual for driving on hills. See page 57.
Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 34.
Never operate on hills too steep for the vehicle or for your abilities.
Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 15
.
>15
11
SAFETY
Rider Safety
Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 59.
Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill. See page 34.
Always follow the procedures outlined in this manual for crossing the side of a hill. See page 58.
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 60.
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 60.
12
Rider Safety
Always follow the procedures outlined in this manual for operating over obstacles. See page 63.
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 56.
Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page
62.
Always follow the procedures outlined in this manual for driving in reverse. See page 64.
SAFETY
13
SAFETY
Rider Safety
Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.
Never modify the vehicle through improper installation or use of accessories.
Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing.
See pages 66-69. Allow a greater distance for braking.
Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party. Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.
Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.
14
SAFETY
Rider Safety
Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.
Always unlock the steering before starting the engine. See page 31.
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated area.
• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
For more information about safety, contact an authorized
POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.
15
SAFETY
Safe Riding Gear
Always wear protective clothing to reduce the chance of injury.
Helmet
Long
Sleeves
Eye Protection
Gloves
Long Pants
Boots
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. A passenger (on approved models) should wear a helmet that includes a rigid chin guard.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
E 4
051039
0006.31
16
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.
17
SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
2x4
H
E
Trip 1
88 mi
F
RPM
H
H
General
Alert Reverse
Override
Warning
Age 16
Alert
H
Hill
Operation
Alert
18
SAFETY
Safety Labels and Locations
General Alert
(Multi-Lingual)
Before you operate or ride this vehicle, read the owner’s manual.
7174362
PASSENGER
UNDER
12
Reverse Override Warning
/4X4
Caution
WARNING
Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.
CAUTION
Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.
7175512
Hill Operation Alert
• Never operate this vehicle on HILLS steeper than 15 degrees 15
.
• To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.
7174361
Tire Pressure/Load Alert
TIRE PRESSURE IN PSI (KPa):
Front: 7.0 psi (48.3 kPa)
Rear: 5.0 psi (34.5 kPa)
MAXIMUM WEIGHT CAPACITY 735 lbs.
(333 kg)
INCLUDES WEIGHT OF OPERATOR,
PASSENGER, CARGO AND
ACCESSORIES.
Read Owner’s Manual for more detailed loading information.
7176783
Tire Pressure/Load
Alert
H
19
SAFETY
Safety Labels and Locations
Rack
Warning
H
H
H
Box
Warning
Clutch Cover
Alert
(under seat)
Hitch
Capacity
Label
Rack Warning, Front
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum combined Front Rack and Container Load: 120 lbs. (54 kg)
7175847
Clutch Cover Alert
20
Safety Labels and Locations
Hitch Capacity Label
TRAILER MAX WEIGHT:
1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15
GRADE
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)
Box Warning
WARNING
Remove flammable material containers from box before filling.
WARNING
Passengers can be thrown off. This can cause serious injury or death.
Never carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
7173890
SAFETY
7170509
21
FEATURES AND CONTROLS
Switches
Main Key Switch
Use the main key switch to start the engine. See page 51.
End all electrical power to the vehicle.
LIGHTS ON position turns the headlights on.
Start the engine. The headlights are not on in this position.
After starting the engine, release the key switch to the POSITION LIGHTS ON position.
4X4 Switch
Use the 4X4 switch to engage
ADC 4X4, 4X4, 2X4 or TURF mode. See pages 32-33. The vehicle automatically engages
4X4 when operating in reverse if the switch is set to either 4X4 position.
E
Trip 1
88 88 mi
Main Key
Switch
4X4
Switch
22
FEATURES AND CONTROLS
Switches
Engine Stop Switch
The engine will not start or run when the switch is in the
OFF position.
Trip 1 RPM
88 88 km mi
2x4
OFF
RUN
Push the stop switch down to stop the engine quickly. Pull the stop switch up to the
RUN position before attempting to start the engine.
Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.
Hazard Switch
Headlight
Switch
Override
Switch
Horn
Switch
Engine
Stop
Switch
Hazard
Switch
Turn Signal
Switch
Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.
Turn Signal Switch
Push the toggle switch either left or right to activate the corresponding turn signal light. Return the toggle to the center position to end the signal.
Horn Switch
Press the horn switch to sound the horn.
Momentary High Beam Switch
Press this switch with your left forefinger to activate the headlight high beam.
The lights will return to low beam when the switch is released.
Momentary High-Beam
Switch
23
FEATURES AND CONTROLS
Switches
Override Switch/MODE Button
This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and press the override switch.
Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button.
The reverse override button also acts as a MODE button when held down for approximately one half second. See the instrument cluster information beginning on page 38.
Tip: The override button will not function as a MODE button if the transmission is in reverse.
Headlight Switch
The main key switch must be on and the engine stop switch must be in the RUN position to operate the headlight switch.
High Beam
Low Beam
24
FEATURES AND CONTROLS
Mirrors
Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.
Throttle Lever
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.
Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.
Press the throttle lever to increase engine speed and vehicle movement.
Release the lever to reduce engine speed and vehicle movement.
Electronic Throttle Control
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.
25
FEATURES AND CONTROLS
Brake Lever
Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.
Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
26
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master cylinder before each ride.
1. Position the vehicle on a level surface.
Master Cylinder
2. Position the handlebars so the master cylinder is level.
3. View the brake fluid level through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full.
When fluid is low, the eye will be clear.
Indicator
Window
4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
27
FEATURES AND CONTROLS
Parking Brake
Locking the Parking Brake
1. Place the transmission in
PARK.
2. Squeeze and release the brake lever two or three times, then squeeze and hold.
3. Push the parking brake lock forward to engage the lock.
4. Release the brake lever.
5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.
Operating the vehicle while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the vehicle if leaving it parked on a hill. Another option is to park the vehicle in a sidehill position. Never depend on the parking brake alone if the vehicle is parked on a hill. Always block the wheels to prevent rolling.
28
FEATURES AND CONTROLS
Auxiliary Foot Brake
Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Since this is a rear brake only, it will not be as effective as the all-wheel single lever system.
The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.
If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.
Brake Fluid Level
Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the front storage box. See page 37.
Maintain the fluid level between the maximum and minimum marks. Use
DOT 4 brake fluid only.
NOTICE: Do not use ADC fluid in the brake fluid reservoir. ADC fluid will damage the rubber components of the brake system.
Auxiliary
Foot Brake
Brake Fluid
Reservoir
29
FEATURES AND CONTROLS
Automatic Transmission Gear Selector
The transmission gear selector is located on the right side of the vehicle.
H: High Gear
L: Low Gear
N: Neutral
R: Reverse
P: Park
Gear
Selector
To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.
NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
Whenever the vehicle is left unattended, always place the transmission in PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.
30
FEATURES AND CONTROLS
Fuel Tank Cap
Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel .
Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.
The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.
Trip 1
88 88 mi
RPM
Fuel Tank
Cap
2x4
Steering Lock
Lock the steering to prevent unauthorized use or theft of the vehicle.
1. Turn the handlebars to the full right position.
Tip: The handlebars may also be locked in the full left position.
2. Insert the steering lock key and turn it clockwise.
3. Remove the key. Place the steering lock keys in a safe place.
The lock must be replaced if the keys are lost.
4. Reverse the procedure to unlock the steering.
The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.
31
FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system is controlled by the 4X4 switch.
ADC 4X4
ADC 4X4 Mode
When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline.
Always move the 4X4 switch to
ADC 4X4 before ascending or descending a hill. See page 34.
4X4 Mode
When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.
4X4 Switch
When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction.
When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.
Tip: The override switch allows activation of 4X4 in reverse if the 4X4 switch is on. See page 24.
32
FEATURES AND CONTROLS
All Wheel Drive System
2X4 Mode
When the switch is on 2X4, the vehicle is in two-wheel drive at all times.
TURF Mode
When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns. Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage. DO
NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Always operate in ADC 4X4 or 4X4 on these types of terrain.
Operating in TURF mode when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.
Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to
4X4 or ADC 4X4 while the rear wheels have traction or are at rest.
33
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the following conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (24 km/h) or less
• The throttle must be closed (throttle lever released)
• The transmission must be in gear (high, low or reverse)
Disengaging Active Descent Control
The ADC system will automatically disengage if at least one of the following conditions occur:
• The 4X4 switch is moved out of the ADC 4X4 position
• Vehicle speed exceeds 15 mph (24 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
34
FEATURES AND CONTROLS
Passenger Seat
Always make sure the passenger seat lock-out is functioning properly before operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always return the seat to the 1-up position for single-rider operation.
Never carry cargo in the rear box when operating the vehicle in the 2-up mode with a passenger.
Seat Conversion
1. Make sure the cargo box dump latch is securely latched. See page
69.
2. Slide the seat latch levers inward to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
Operator Backrest
Latches
Release Locks
Passenger
Backrest
35
FEATURES AND CONTROLS
Passenger Seat
Seat Conversion
5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desired position. Release the latch, making sure it locks into one of the three operating positions.
Tip: The backrest must be moved out of the lowest position before it can be secured in the upright position. The lowest position is for seat storage only.
Do not leave the backrest in the lowest position. Always adjust the backrest to one of the three operating positions.
6. Lower the operator backrest to create the passenger seat.
Two retaining pins under the seat should fit into the two grommets on the seat base.
7. Test the passenger seat lockout by attempting to release the cargo box dump latch.
See page 69. If the dump latch releases, the seat is not secure. Repeat the set-up procedure. If the lock-out is not working properly, do not allow a passenger to ride the vehicle . See your POLARIS dealer for service.
Passenger
8. To return the vehicle to single-rider operation, reverse all steps. Always lower the passenger backrest to the lowest position before folding it down into the cargo box. Slide the seat latch levers outward to secure the locks.
Backrest
Adjustment
Latch
Locked
36
FEATURES AND CONTROLS
Front Box/Compartment
Release the front box anchor latches and remove the box assembly to gain access to the front compartment. To reinstall the box, hold the box as shown in the rack illustration. Position the front edge in the tabs, then push the box downward and secure the latches.
Access the following components in the front compartment:
• Radiator cap
• Brake fluid reservoir
• ADC fluid reservoir
• Battery
• Coolant recovery bottle cap
• Electrical/fuse/relay components
Latches
Battery
Brake Fluid
Reservoir
ADC Fluid
Reservoir
Coolant
Bottle Cap
Radiator
Cap
Electrical/Fuse/Relay
37
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage vehicle components. Wash the vehicle by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
Digital/Analog Gauge
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).
Indicator Lamps
Speedometer
E
Trip 1
88 : 88 mi
F
RPM
Rider
Information
Center
38
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Indicator Lamps
Lamp Indicates
Vehicle
Speed
Over
Temperature
Neutral
High Beam
Direction
Indicators
Condition
When standard mode is selected, speed displays in miles per hour.
When metric mode is selected, speed displays in kilometers per hour.
This lamp flashes to indicate an overheated engine. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine power.
This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
This lamp illuminates when the headlamp switch is set to high beam.
A direction indicator flashes when a turn signal is active. Both indicators flash when the hazard signal is active.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.
39
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.
The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 43.
2
E
Trip 1
1
3
8
7 6
88 :
km mi
88
5
4
40
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
1.
Gear Display - This area displays gear shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
-- = Gear Signal Error (or shifter between gears)
2.
Fuel Gauge Display - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer.
3.
Information Display - This area displays odometer, trip meter, engine hour meter, engine speed and programmable service hour interval.
4.
Active Descent Control Display This icon displays when ADC is active. See page 34.
5.
Clock Display - The clock displays time in a 12-hour or 24-hour format. If the engine is turned off, press the MODE button. The time will display for 5-10 seconds. See page 43 for resetting instructions.
6.
Service Reminder Display - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 43 for resetting instructions.
7.
4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 or 4X4).
8.
Turf Mode Indicator - This icon displays when Turf Mode is engaged.
41
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric units of measurement.
Tip: To exit the set-up mode at any time, wait 10 seconds.The display automatically exits and returns to the odometer display.
Distance
Fuel
Temperature
Time
Standard Display
Miles
U.S. Gallons
Fahrenheit
12-Hour Clock
Metric Display
Kilometers
Liters, Imperial Gallons
Celsius
24-Hour Clock
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON position.
4. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to the next display option.
6. Repeat the procedure to change remaining display settings.
42
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode
The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
43
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Programmable Service Interval
When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only.
Please see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
44
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Engine Error Codes
The error screen displays only when the CHECK
ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off.
The code and message is lost, but will reappear if the fault reoccurs after restarting the engine.
Error Code
Number (0-9)
Suspect Parameter
Number (SPN)
If the CHECK ENGINE light illuminates, retrieve the error codes from the display. Please see your Polaris dealer for all major repairs.
Failure Mode Indicator (FMI)
1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code menu.
3. Record the numbers displayed in the gear position (if any), clock and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 46-47 for code definitions and failure descriptions. Please see your Polaris dealer for all major repairs.
45
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
Shorted Load: The wires leading to the item listed in the chart are shorted together, or the item has shorted internally.
Short-to-Battery: The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage.
46
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Sportsman 550 X2 Diagnostic Codes
Component
Throttle Position Sensor
Engine Temperature Sensor
Intake Air Temperature Sensor
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 Manifold Absolute Pressure Sensor
Crankshaft Position Sensor
Gear Sensor Signal
Fan Relay Driver Circuit
Idle Air Control
Voltage Too Low
Circuit Fault
Voltage Too Low (to Calibrate)
Voltage Too High
Injector 1 (MAG)
Signal Fault
Driver Circuit Open/Grounded
Driver Circuit Short to B+
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded
Driver Circuit Short to B+
Fuel Pump Driver Circuit Driver Circuit Open/Grounded
Driver Circuit Short to B+
Driver Circuit Open/Grounded
Driver Circuit Short to B+
Driver Circuit Grounded
Starter Enable Circuit
All Wheel Drive Control
System Power
Throttle Safety Signal
Shorted Load*
Driver Circuit Short to B+
Driver Circuit Short to B+
Voltage Too High
Voltage Too low
Voltage Too High
Voltage Too Low
Signal Out of Range
Throttle Stuck
*Assumes unipolar configuration of stepper motor
1347
1347
1071
1071
520193
520193 11
1321 3
520207
168
168
3
3
4
5
3
5
3
5
520194
520194
520194
520194
2
7
3
4
102
636
523
523
523
651
651
1268
1268
110
110
105
105
102
SPN
51
51
110
110
3
5
2
5
3
4
3
4
8
16
0
3
4
3
FMI
3
4
3
4
47
OPERATION
WARNING
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.
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 31. Always exercise extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 76. 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 49.
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.
48
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
Passenger seat lock-out
Brake system/lever travel
Brake fluid
Auxiliary brake
Front suspension
Rear suspension
Steering
Steering lock
Tires
Wheels/fasteners
Remarks
Ensure proper operation
Ensure proper operation
Ensure proper level
Ensure proper operation
Inspect, lubricate if necessary
Inspect, lubricate if necessary
Ensure free operation
Unlock the steering; 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
Switches
Engine stop switch
Mirrors
Turn signals, indicators
Air filter, pre-filter
Headlamp
Brake light/taillight
Riding gear
ADC Fluid
Ensure proper level
Inspect for leaks
Ensure proper operation
Ensure operation
Ensure proper operation
Adjust for best side/rear vision
Ensure operation
Inspect, clean
Check operation, apply POLARIS dielectric grease when lamp is replaced
Check operation, apply POLARIS dielectric grease when lamp is replaced
Wear approved helmet, goggles, and protective clothing
Ensure proper level
31
76
89
90
-
25
114
94
94
95
-
22
23
25
23
96
24
98
Page
35
26
91
27
29
75
75
-
31
101
16
84
49
OPERATION
Safe Operation Practices
1. Complete the recommended safety training before operating this vehicle.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.
4. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable).
5. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
6. Drive in a manner appropriate for your skills, your passenger’s skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
7. Never consume alcohol or drugs before or while operating this vehicle.
8. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
9. Never operate a damaged vehicle. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.
10. 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.
11. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
12. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
50
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well-ventilated area.
2. Place the transmission in PARK.
3. Lock the parking brake.
Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged.
4. Sit on the vehicle and move the engine stop switch to RUN.
Tip: Do not press the throttle while starting the engine.
5. Turn the ignition key past the 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.
51
OPERATION
Driving Procedures
1. Wear protective riding gear. See page 16.
2. Perform the pre-ride inspection. See page 49.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and brakes on level surfaces.
52
OPERATION
Turning the Vehicle
1. Before turning, activate a turn signal to alert others of your intentions.
Activate the left signal before a left turn. Activate the right signal before a right turn.
2. Steer in the direction of the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.
3. Practice making turns at slow speeds before attempting to turn at faster speeds.
Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.
53
OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up vehicle. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 16.
4. Perform the pre-ride inspection. See page 49.
5. Convert the seat for 2-up riding. See page 35. Always make sure the passenger seat lock-out is functioning properly before carrying a passenger.
6. Lock the parking brake.
7. Mount the vehicle from the left side. After the operator is seated, the passenger should mount the vehicle from the left side. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts.
8. Allow a passenger to ride only in the approved passenger seat.
9. Never carry more than one passenger.
10. Slow down. Control may be more difficult with a passenger on board. Allow more time and distance for braking.
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.
54
OPERATION
Driving with a Passenger
12. Do not cross a hillside with a passenger on board. See page 58.
13. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.
14. Make sure the passenger understands the importance of "active riding." When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.
55
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. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.
4. Be alert. Watch the trail. Avoid quick, sharp turns
5. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
56
Driving Uphill
OPERATION
15
Maximum
Whenever traveling uphill, follow these precautions:
1. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 34.
2. Drive straight uphill.
3. Avoid steep hills (15
maximum).
4. Always check the terrain carefully before ascending any hill.
5. Never climb hills with slippery or loose surfaces.
6. Keep both feet on the footrests.
7. Shift body weight uphill. A passenger should also shift body weight uphill.
8. Proceed at a steady rate of speed to avoid stalling.
9. Never open the throttle suddenly or make sudden gear changes.
10. Be alert. Be prepared to take emergency action. This may include dismounting quickly.
57
OPERATION
Driving on a Sidehill (Sidehilling)
Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:
1. Slow down.
2. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.
3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.
4. If the vehicle begins to tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately !
58
Driving Downhill
OPERATION
15
Maximum
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 34.
3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.
4. Slow down. Never travel down a hill at high speed.
5. Drive straight downhill. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.
6. Shift body weight uphill. A passenger should also shift body weight uphill.
7. Apply the brakes slightly to aid in slowing. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.
59
OPERATION
Turning Around on a Hill (K-Turn)
If the vehicle stalls while climbing a hill, never back it down the hill!
Use the K-turn to turn around.
8 ft. (2.4 m)
60
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Never operate in TURF mode while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 34.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A passenger should not remount until the vehicle returns to firm, level ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill. A passenger should not remount until the vehicle returns to firm, level ground.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly , controlling speed with the brake lever, until the vehicle is on more level ground.
61
OPERATION
Driving Through Water
Maximum Depth
Follow these procedures when driving through water:
1. Check water depth and current before crossing.
2. Choose a crossing where both banks have gradual inclines.
3. Drive slowly. Avoid rocks and obstacles.
4. Avoid operating in water deeper than the bottom of the footrests. If it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.
NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 71. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings .
If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 104, then see your dealer for service at the first opportunity.
5. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
62
Driving Over Obstacles
OPERATION
Follow these precautions when operating over obstacles:
1. Always check for obstacles before operating in a new area.
2. Be alert. Watch the terrain. Use extra caution.
3. Never operate over large obstacles.
4. Avoid hazards such as logs, rocks and low branches.
5. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.
63
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Drive slowly. Apply the brakes lightly for stopping.
4. Avoid turning at sharp angles.
5. Never open the throttle suddenly.
6. Do not use the override switch unless additional wheel speed is required for vehicle movement. Use with caution.
NOTICE: Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust, resulting in engine popping and/or engine damage.
64
Parking on an Incline
OPERATION
Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always block the rear wheels on the downhill side.
65
OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo:
• Read and understand the load distribution warnings listed on the vehicle warning labels.
• Never carry cargo in the rear box when operating the vehicle in the 2-up mode with a passenger.
• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
• Never exceed the stated load capacity for this vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.
• WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low as possible. Carrying a high load raises the center of gravity and creates a less stable operating condition. Reduce load weight when cargo is high.
When handling off-centered loads that cannot be centered, secure the load and operate with extra caution. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.
• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift and create unstable operating conditions, which could result in loss of control of the vehicle. Always be sure that the cargo bed is lowered and latched before moving the vehicle.
• USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing the machine to overturn.
• BALANCE LOADS proportionally between the front rack and cargo bed, but do not exceed the stated load capacity. Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn.
• USE EXTREME CAUTION when applying brakes with a loaded vehicle.
Avoid terrain or situations that may require backing downhill.
• Always attach the tow load to the hitch point designated for your vehicle.
• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.
• TOWING is approved OFF-ROAD ONLY.
• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.
66
OPERATION
Hauling Cargo
Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of this manual.
1. Cargo weight should be mounted as low as possible.
2. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.
3. Always load the cargo box with the load as far forward as possible.
4. Do not obstruct the headlight beam with cargo.
5. Use low forward gear when hauling or towing heavy cargo to extend belt life.
6. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling, and control may be affected.
7. Slow down.
8. Make sure the cargo box dump latch is securely latched before loading and operating. Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured.
67
OPERATION
Hauling Cargo
Towing Loads
Towing is approved OFF-ROAD ONLY. See your Polaris dealer about configuring the vehicle to be certified to tow a trailer on-road.
• Do not tow any trailer on a grade steeper than 15
• Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer. If towing a load, reduce rear box cargo weight by the amount of tongue weight.
• The combination of rear box cargo weight and tongue weight must not exceed the rear box capacity.
• The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your POLARIS warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARISapproved (or equivalent) accessories designed for use on this vehicle.
Maximum
4" (10 cm)
Do not exceed the following maximum capacities when towing. Avoid towing on inclines.
Maximum Towing Capacities
Maximum Towed Load (Level Ground)
Maximum Vertical Hitch Weight
1500 lbs. (680 kg)
150 lbs. (68 kg)
68
OPERATION
Hauling Cargo
Dumping Cargo
1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Dismount the vehicle.
5. Lower the tailgate.
If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible.
6. Pull the cargo box release strap upward.
7. Lift the front of the cargo box and dump the cargo.
8. Lower the cargo box and make sure the release latch is secured.
9. Secure the tailgate.
Cargo Box
Release Strap
Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle. The cargo box could close unexpectedly and injure the driver. The rear tires will also catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position.
69
EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.
Spark Arrestor
Your Polaris vehicle has a spark arrestor that was designed for on-road and off-road operation. It is required that this spark arrestor remain installed and functional when the vehicle is operated.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
Electromagnetic Interference
This spark ignition system complies with Canadian standard ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
70
MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page
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.
71
MAINTENANCE
Periodic Maintenance Chart
Improperly performing the procedures marked with a n 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.) n Have an authorized POLARIS dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
Item Remarks
Steering
Front suspension
Rear suspension
Tires
Brake fluid level
Brake lever travel
Brake system
Passenger seat lock-out
E
Wheels/fasteners
Frame fasteners
Engine oil level
Air filter, pre-filter
Coolant
ADC fluid
Headlight/taillight
-
-
-
-
Maintenance Interval
(whichever comes first)
Hours Calendar
-
-
-
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
-
-
-
-
Miles
(Km)
-
-
-
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Daily
Daily
Daily
Daily
-
-
-
-
-
-
-
Make adjustments as needed. See Pre-Ride
Checklist on page 49.
Inspect; clean often; replace as needed
Check level daily, change coolant every 2 years
Check level daily, add as needed
Check operation; apply dielectric grease if replacing lamps
72
MAINTENANCE
Periodic Maintenance Chart
Item
E
Air filter, main element
Engine oil change
Maintenance Interval
(whichever comes first)
Hours Calendar
Weekly
Miles
(Km)
-
20 H 1 Month
Monthly
Remarks
Inspect; replace as needed
500 (800) Perform a break-in oil and filter change (see page 78)
100 (160) Inspect periodically
n
Brake pad wear 10 H
Battery 20 H
Rear gearcase oil
Transmission oil
25 H
25 H
Demand drive fluid 25 H
Demand drive fluid
(extreme use)
25 H
General lubrication
Shift linkage n Steering
Front suspension
Rear suspension n E Throttle Cable/
ETC Switch
E Throttle Body
Intake Duct
Drive belt
Cooling system
Radiator
50 H
50 H
50 H
50 H
50 H
50 H
50 H
50 H
50 H
50 H
Cooling hoses 50 H
Engine oil change 100 H
Oil filter change
Demand drive fluid
(normal use)
100 H
100 H
Rear gearcase oil 100 H
Transmission oil 100 H
Monthly
Monthly
Monthly
Monthly
1 M
3 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
6 M
12 M
12 M
12 M
200 (320) Check terminals; clean; test
250 (400) Inspect level; change yearly
250 (400) Inspect level; change yearly
250 (400) Inspect level
250 (400) Change fluid every 25 hours if ADC is subjected to extreme use. See page 82.
500 (800) Lubricate all fittings, pivots, cables, etc.
500 (800) Inspect, lubricate
500 (800) Lubricate
500 (800) Lubricate
500 (800) Lubricate
500 (800) Inspect; adjust; lubricate; replace if necessary
500 (800) Inspect duct for proper sealing/air leaks
500 (800) Inspect; adjust; 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) Perform a break-in oil change at one month
1000 (1600) Replace with oil change
1000 (1600) Change fluid
1000 (1600) Change fluid
1000 (1600) Change fluid
73
MAINTENANCE
Periodic Maintenance Chart
Item
Fuel system
Maintenance Interval
(whichever comes first)
Hours Calendar
100 H
100 H
100 H
12 M
12 M
12 M
Remarks
Miles
(Km)
1000 (1600) Check for leaks at tank cap, lines, filter, pump; replace lines every two years
1000 (1600) Inspect
1000 (1600) Inspect
Engine mounts
Exhaust muffler/ pipe n E Spark plug
Wiring n n
Clutches (drive and driven)
Front wheel bearings n
n
Brake fluid
ADC fluid
Spark arrestor n E Valve clearance n Toe adjustment
100 H
100 H
100 H
100 H
200 H
200 H
300 H
1000 H
12 M
12 M
12 M
12 M
24 M
24 M
36 M
-
-
1000 (1600) Inspect; replace as needed
1000 (1600) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
1000 (1600) Inspect; clean; replace worn parts
1000 (1600) Inspect; replace as needed
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 Headlight aim -
Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service n Have an authorized POLARIS dealer perform these services.
74
MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 71. Items not listed in the chart should be lubricated at the General Lubrication interval.
The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
Item Recommended
Lubricant
Engine Oil
Transmission
Oil
PS-4 PLUS
Performance
Synthetic 2W-50
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)
32 oz.
(950 ml)
9.3 oz.
(275 ml)
6.1 oz.
(180 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)
10-14 ft. lbs.
(14-19 Nm)
11 ft. lbs.
(15 Nm)
10-14 ft. lbs.
(14-19 Nm)
---
---
Inspection
Procedure
Page 76.
Page 80.
Page 82.
Page 86.
Page 27.
Page 84.
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
75
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 75 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 127 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.
76
MAINTENANCE
Engine Oil
Oil Level
Check the oil level when the engine is cold. Never check the oil with the engine running.
1. Position the vehicle on a level surface.
2. Access the oil dipstick and fill tube from the left side of the vehicle.
Remove the dipstick. Wipe it dry with a clean cloth.
3. Reinstall and tighten the dipstick.
4. Remove the dipstick and check the oil level.
5. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.
6. Reinstall and tighten the dipstick.
Dipstick
Full Add
77
MAINTENANCE
Engine Oil
Oil and Filter Change
See the table on page 75 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 71. Always change the oil filter whenever changing oil.
Drain Plug to front
Filter Access
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three minutes.
3. Stop the engine.
4. Clean the area around the drain plug.
5. Place a drain pan under the crankcase.
6. Remove the drain plug. Allow the oil to drain completely.
Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
7. Install a new sealing washer on the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.
8. Reinstall the drain plug. Torque to specification.
78
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.
13. Remove the dipstick. Add the proper amount of the recommended oil. Do not overfill.
14. Reinstall the dipstick.
Oil Filter
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
21. Dispose of used filter and oil properly.
79
MAINTENANCE
Transmission Oil
POLARIS recommends the use of POLARIS AGL PLUS Transmission
Fluid for this transmission. See the table on page 75 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 71. See page 127 for the part numbers of
POLARIS products.
Maintain the oil level at the bottom of the fill plug hole. The fill plug is located on the right side of the vehicle behind the footwell. The drain plug is located on the bottom left side of the gearcase.
Oil Check
1. Remove the footwell (see page 93).
2. Remove the fill plug. Check the oil level.
3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to specification.
5. Reinstall the footwell.
Drain Plug
Fill
Level
Fill Plug
80
MAINTENANCE
Transmission Oil
Oil Change
1. Remove the footwell.
2. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Remove the fill plug. Add the proper amount of the recommended oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Reinstall the footwell.
8. Dispose of used oil properly.
81
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
See the table on page 75 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 71.
NOTICE: Change the demand drive fluid every 25 hours if the ADC unit is exposed to extreme use.
ADC Extreme Use Definition
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation.
Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 127 for the part numbers of
POLARIS products.
Maintain the fluid level at the bottom of the fill hole threads. See below for capacity. The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.
Fill
Level
Fill
Plug
Drain Plug
82
MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Check
1. Position the vehicle on a level surface. Remove the fill plug. Check the fluid level.
2. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
3. Reinstall the fill plug. Torque to specification.
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug.
2. Place a drain pan under the demand drive unit. Remove the drain plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to specification.
4. Add the proper amount of the recommended fluid.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks. Dispose of used fluid properly.
83
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Level
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 71.
We recommend the use of POLARIS Demand Drive Plus Fluid for the
ADC unit. Maintain the fluid level between the minimum and maximum marks on the reservoir. See page 127 for the part numbers of POLARIS products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in the hydraulic system.
1. Remove the front box.
2. View the fluid level in the reservoir.
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 box.
84
MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Change
1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.
2. Thoroughly clean the areas around and on the ADC reservoir and bleeder valves
(one on each side of the differential).
3. Remove the reservoir cap and diaphragm assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir. Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.
4. Fill the reservoir to the maximum line with fresh fluid.
Bleeder
Screw
Cap
Bleeder
Valve
Screw
5. Remove the protective caps from the bleeder valves.
6. Slowly loosen one of the bleeder valve screws (turn counter-clockwise) and allow fluid and trapped air to flow from the fitting.
Tighten the screw when clean fluid begins to flow. Repeat this step for the remaining valve.
IMPORTANT: Close the bleeder valve screws before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.
7. Torque the bleeder valve screws to 80 in. lbs. (9 Nm). Reinstall the bleeder valve caps.
8. Add fresh ADC fluid to the reservoir until the level is between the minimum and maximum marks. Make sure the reservoir is free of debris.
9. Reinstall the cap securely. Clean up any drips or spills.
85
MAINTENANCE
Rear Gearcase Oil
See the table on page 75 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 71. See page 127 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 .
4. Reinstall the fill plug. Torque to specification.
Drain Plug
86
MAINTENANCE
Rear Gearcase Oil
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain hole.
3. Remove the drain plug. Allow the oil to drain completely.
4. Clean and reinstall the drain plug with a new sealing washer. Torque to specification.
5. Remove the fill plug. Add the proper amount of the recommended oil. Do not overfill .
6. Reinstall the fill plug. Torque to specification.
7. Check for leaks.
8. Dispose of used oil properly.
87
MAINTENANCE
Cooling System
The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose.
As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle. As engine coolant temperature decreases the contracting (cooled) coolant is drawn back up from the bottle, past the pressure cap, and into the radiator.
Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.
POLARIS recommends the use of POLARIS 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
127 for the part numbers of POLARIS products.
Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.
88
MAINTENANCE
Cooling System
Recovery Bottle Coolant
The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front storage compartment.
1. View the fluid level in the bottle.
2. If the level is low, remove the front box.
3. Remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).
4. Reinstall the cap.
5. Reinstall the front box.
Maximum
Mark
Minimum
Mark
Recovery
Bottle Cap
89
MAINTENANCE
Cooling System
Radiator Coolant
To ensure that the coolant maintains its ability to protect the engine,
POLARIS recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.
Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.
Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.
1. Remove the front box.
2. Remove the pressure cap.
3. Using a funnel, slowly add coolant through the radiator filler neck.
4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.
5. Reinstall the front box.
Radiator
Cap
90
MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting.
Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.
An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level.
Do not overfill.
The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.
1. Always keep brake fluid at an adequate level. See page 27.
2. Check the brake system for fluid leaks.
3. Check the brakes for excessive travel or spongy feel.
4. Check the friction pads for wear, damage and looseness. Replace brake pads when they are worn to 3/64" (1 mm).
5. Check the security and surface condition of the disc.
3/64" (1 mm)
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 29.
91
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).
Severe injury or death can result from improper toe alignment and adjustment.
Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.
1. Position the vehicle on a level surface.
2. Place the handlebars in a straight-ahead position.
Stand
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.
String
2
4. Measure the distance from the string to the rim at the front (1) and
1 rear (2) of the front rim.
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.
Steering Assembly
The steering assembly of the vehicle should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your
POLARIS dealer for service before operating the vehicle.
92
MAINTENANCE
Seat Removal
1. Remove any cargo from the cargo box before removing the seat.
2. Stand beside the vehicle. Pull the cargo box release strap upward. Lift the front of the cargo box.
3. Grasp edge of the seat near the opposite rear corner.
4. Pull upward abruptly to disengage the under-seat fasteners.
5. Remove the seat.
Side Panel/Footwell Removal
1. Remove the seat before removing a side panel.
2. To remove a side panel or footwell, remove the fasteners securing it to the frame. Lift the right side panel upward while removing it to clear the shifter knob.
Screw
Plastic Rivet
Plastic Rivet
Hex Head Screw
93
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 128 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.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Loosen the wheel nuts slightly.
Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer.
5. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.
6. Remove the wheel nuts.
7. Remove the wheel.
94
MAINTENANCE
Tires
Wheel Installation
1. Place the transmission in PARK.
2. Lock the parking brake.
3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation (if equipped).
4. Install the wheel nuts and finger-tighten them.
5. Lower the vehicle to the ground.
6. Torque the wheel nuts to specification.
Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn. Always ensure that all nuts are torqued to specification.
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 service.
Wheel Type
Aluminum
Steel
Nut Type
Lug Nut
Lug Nut
Nut Torque
75 ft. lbs. (102 Nm)
45 ft. lbs. (61 Nm)
95
MAINTENANCE
Air Filter
1. Remove the seat. See page 93.
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
96
MAINTENANCE
Fuse Replacement
If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse. Spare fuses are provided in the fuse box.
1. Remove the front box.
2. Remove the fuse box cover.
3. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage rating.
4. Reinstall the fuse box cover.
5. Reinstall the front box.
Fuse Box
97
MAINTENANCE
Lights
Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Always make sure lights are adjusted properly for best visibility.
Headlight Lamp Replacement
When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.
1. Remove the five (5) headlight pod screws.
2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
Hot components can cause burns to skin. Allow lamps to cool before servicing.
3. Unplug the headlamp from the wiring harness. Be sure to pull on the connector, not on the wiring.
4. Turn the lamp counterclockwise to remove it.
5. Install the new lamp. Make sure the tab on the lamp locates properly in the housing.
6. Reassemble the pod.
98
MAINTENANCE
Lights
High Beam Adjustment
The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.
25 ft. (7.6 m)
Lamp Center Height
2 " (5 cm)
1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height.
3. Start the engine.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be two inches (5 cm) below the mark on the wall. Include rider weight on the seat when measuring.
5. The adjustment screw is located on the right side of the headlight pod. To adjust the beam, loosen the screw.
Adjust the headlamp to the desired position, then tighten the screw.
Adjustment
Screw
99
MAINTENANCE
Lights
Low Beam Adjustment
The low beam can be adjusted slightly upward or downward.
1. Loosen the phillips screw located at the rear of the headlamp.
2. Tilt the headlamp upward or downward.
3. Tighten the screw.
Phillips Screw
Headlight Housing Replacement
1. Remove the five (5) headlight pod screws.
2. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.
3. Unplug the headlamp from the wiring harness.
4. Use a small screwdriver to remove the o-rings from the headlight mounting tabs.
5. Pull the headlight housing up to release it from the locking tabs.
6. Carefully pull the assembly up and out of the pod.
7. Reverse the steps to install the new housing and reassemble the pod.
Front Turn Signal Replacement
If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly.
100
MAINTENANCE
Lights
Lower Headlamp Replacement
1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly.
2. Remove the headlamp and install the new headlamp.
3. Reinstall the harness assembly into the headlight assembly.
4. Turn the headlight harness clockwise to secure the headlamp.
Harness
Taillight/Brakelight Lamp Replacement
1. Open the tailgate.
2. Remove the two screws near the tailgate latch.
3. Grasp the entire taillight assembly and pull it away from the vehicle.
4. Remove the harness connector from the back of the light assembly.
5. Turn the lamp counterclockwise to remove it.
6. Apply dielectric grease to the socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
Lamp
Screws
101
MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 128 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
9-11 ft. lbs.
(12-15 Nm)
17-20 ft. lbs.
(23-27 Nm)
Spark Plug Inspection
Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 103.
A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.
2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove it.
3. Reverse the procedure for spark plug installation. Torque to specification.
102
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.
103
MAINTENANCE
Vehicle Immersion
If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine. If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined below.
1. Move the vehicle to dry land or at the very least, to water below the footrests.
2. Check the air box. If water is present, dry the air box and replace the filter with a new filter.
3. Remove the spark plugs.
4. Turn the engine over several times using the electric start.
5. Dry the spark plugs. Reinstall the plugs or install new plugs.
6. Attempt to start the engine. If necessary, repeat the drying procedure.
NOTICE: Serious damage can occur after immersion if fluids are not changed promptly. See your dealer as recommended .
7. Take the vehicle to your dealer for service as soon as possible, whether you succeed in starting it or not.
8. If water has been ingested into the PVT, follow the procedure on page 108 for drying out the PVT.
104
MAINTENANCE
Spark Arrestor
WARNING
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.
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and release the throttle lever several times to purge carbon from the system.
5. If carbon comes out of the exhaust, cover or plug the exhaust outlet(s). Wear protective gloves.
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. Lock the parking brake. Repeat steps 4 to 6 until no more particles are expelled.
9. Stop the engine. Allow the arrestor to cool.
10. Reinstall the arrestor plug and remove the exhaust outlet cover or plug.
105
MAINTENANCE
PVT System
WARNING
Failure to comply with the instructions in this warning can result in severe injury or death.
Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:
• Always follow all recommended maintenance procedures. 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.
106
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.).
107
MAINTENANCE
PVT System
When To Use Low Range and High Range
The air temperature in the clutch cover is substantially reduced by using low range while operating at low ground speeds. Reducing the temperature inside the clutch cover greatly extends the life of the PVT components (belt, cover, etc.).
Condition
Operating at speeds less than 7 MPH (11 km/h)
Towing heavy loads
Operating in rough terrain (swamps, mountains, etc.)
Operating at speeds greater than 7 MPH (11 km/h)
Range to Use
Low
Low
Low
High
PVT Drying
There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operating.
1. Position the vehicle on a level surface.
2. Remove the drain plug. Allow the water to drain completely. Reinstall the drain plug.
3. Start the engine. Place the transmission in PARK.
4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 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.
108
MAINTENANCE
Battery
WARNING
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
Your vehicle is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.
Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Battery Removal
1. Remove the front box.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Disconnect the battery hold-down strap.
5. Lift the battery out of the vehicle.
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. Coat the terminals with dielectric grease or petroleum jelly.
4. Secure the battery hold-down strap.
5. Connect and tighten the red (positive) cable first.
6. Connect and tighten the black (negative) cable last.
7. Verify that cables are properly routed. Cables should be safely tucked away at the front and rear of the battery.
8. Install the front box.
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.
Tip: Power plug leads may need to be bent down so that the battery cover can be installed.
POLARIS recommends maintaining battery charge by using a
POLARIS Battery Tender charger or by charging about once a month to make up for normal self-discharge. Battery Tender can be left connected during the storage period, and will automatically charge the battery if the voltage drops below a pre-determined point. See page 127 for the part numbers of POLARIS products.
111
MAINTENANCE
Battery
Battery Charging
The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.8 or greater.
3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the guidelines on the next page for recharging.
112
MAINTENANCE
Battery
Battery Charging
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
Throttle Body/Idle RPM
Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your POLARIS dealer for adjustment.
Throttle Cable Freeplay
1. Remove the four cover screws from the right handlebar control and remove the cover.
2. With the handlebars straight ahead, place very light pressure on the throttle lever. A gap of 2-3 mm should be visible between the throttle arm stop pin and the throttle arm.
If adjustment is needed:
1. Locate the throttle cable adjuster. Squeeze the end of the rubber boot and slide it back far enough to expose the in-line cable adjuster locknut.
2. Loosen the adjuster locknut.
3. Rotate the boot to turn the adjuster until 2-3 mm of freeplay is achieved between the stop pin and the throttle arm. While adjusting freeplay, flip the throttle lever back and forth repeatedly.
(continued on next page)
Arm Stop Pin
Cable
Adjuster
Boot
Lock
Nut
Throttle
Arm
2-3 mm Gap
Adjuster
114
MAINTENANCE
Throttle Cable Freeplay
4. Place the transmission in PARK. Lock the parking brake.
5. Start the engine and allow the idle to stabilize. If necessary, tap the throttle lever to ensure the idle speed settles.
6. If idle speed remains above or below the recommended setting (see specification pages), verify the correct gap. If gap is correct and idle speed is still not satisfactory, please see your POLARIS dealer for service.
7. With the engine running, turn the handlebars fully to the left and right. Tap the throttle lever at each turn, verifying that idle RPM returns to the recommended setting. If idle speed increases, it may be necessary to increase the gap between the stop pin and throttle arm, but do not exceed the recommended 2-3 mm gap.
8. When adjustments are complete, tighten the locknut.
9. Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position.
10. Ensure the control cover seal is in place, then reinstall the cover and screws.
115
MAINTENANCE
Handlebars
The handlebars can be adjusted for rider preference.
Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.
1. Remove the upper headlight pod.
2. Loosen the four handlebar bolts.
3. Adjust the handlebar to the desired height. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.
4. Torque the front two bolts to
10-12 ft. lbs. (14-17 Nm), then torque the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.
Handlebar
Bolts
116
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
117
MAINTENANCE
Transporting the Vehicle
Follow these procedures when transporting the vehicle.
1. Stop the engine.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Always secure the seat in the 1-up position to prevent loss during transporting.
5. Secure the fuel cap and oil cap.
6. Always tie the frame of the vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front Aarm bolt pockets.
7. Remove the key to prevent loss during transporting.
Accessories
Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your vehicle. Always install accessories that are approved by POLARIS for your vehicle.
Please see your POLARIS dealer.
118
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.
119
MAINTENANCE
Cleaning and Storage
Washing the Vehicle
If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items:
• 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.
120
MAINTENANCE
Cleaning and Storage
Storage Tips
NOTICE: Starting the engine during the storage period will disturb the protective film created by fogging and damage could occur. Never start the engine during the storage period.
Clean the Exterior
Make any necessary repairs and clean the vehicle as recommended. See page 119.
Oil and Filter
Change the oil and filter. See page 78.
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 71.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark or contaminated)
• Coolant (test strength/fill)
Stabilize the Fuel
1. Fill the fuel tank.
2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.
121
MAINTENANCE
Cleaning and Storage
Storage Tips
Fog the Engine
1. After stabilizing the fuel, remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear
1/4" hose and a small plastic squeeze bottle filled with the pre-measured amount of oil.
2. Reinstall the spark plugs. Torque to specification.
3. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs.
4. Turn the engine over several times. Oil will be forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.
5. If POLARIS fuel system additive is not used, the fuel tank, fuel lines, and injectors should be completely drained of gasoline.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
96.
2. Clean the air box.
Inspect and Lubricate
Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 71.
Battery Storage
See pages 111-112 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the vehicle with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.
122
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
60).
Drive at a higher speed or use low range more frequently.
See page 108.
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
Climbing over large objects from a stopped position
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.
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 108. 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
Wrong or missing belt
Improper break-in
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 48.
123
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
Check all connections and tighten
Engine Turns Over, Fails to Start
Possible Cause
Out of fuel
Clogged fuel filter
Water is present in fuel
Old or non-recommended fuel
Fouled or defective spark plug(s)
No spark to spark plug
Water or fuel in crankcase
Low battery voltage
Mechanical failure
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
Recharge the battery to 12.8 VDC
See your dealer
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
Leaking exhaust components
Solution
Inspect, clean and/or replace spark plug(s)
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
See your dealer
See your dealer
Check all connections and tighten
Replace with fresh recommended fuel
See your dealer
124
TROUBLESHOOTING
Engine Pings or Knocks
Possible Cause
Poor quality or low octane fuel
Incorrect ignition timing
Incorrect spark plug gap or heat range
Solution
Replace with recommended fuel
See your dealer
Set gap to specs or replace plugs
Engine Runs Irregularly, Stalls or Misfires
Possible Cause
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
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 plug(s)
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Replace with recommended fuel
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
Replace with recommended fuel
See your dealer
Replace with recommended fuel
Solution
Replace with lower octane fuel
Allow engine to warm up before operating and/or stopping
Replace with recommended fuel
Inspect and clean or replace
125
TROUBLESHOOTING
Engine Stops or Loses Power
Possible Cause
Out of fuel
Kinked or plugged fuel vent line
Water is present in fuel
Fouled or defective spark plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
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 plugs
See your dealer
Set gap to specs or replace plug
Check all connections and tighten
Recharge the battery to 12.8 VDC
Replace with fresh recommended fuel
Inspect and clean or replace
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.
126
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
127
SPECIFICATIONS
Sportsman 550 X2
Maximum Weight Capacity
Dry Weight
Fuel Capacity
Engine Oil Capacity
Coolant Capacity
Transmission Oil Capacity
Demand Drive Fluid Capacity
735 lbs. (333 kg) (includes operator, passenger, cargo, accessories)
799 lbs. (362.4 kg)
5.25 gal. (20 l)
2 qts. (1.9 l)
2 qts. (1.9 l)
32 oz. (948 ml)
9.3 oz. (275 ml)
Rear Gearcase Oil Capacity 6.1 oz. (180 ml)
Front Rack/Storage Box Capacity 120 lbs. (54 kg)
Rear Storage Box Capacity
Hitch Tongue Weight
Hitch Towing Rating
Unbraked Trailer Towing
Capacity*
400 lbs. (181 kg)
150 lbs. (68 kg) (Rear box capacity and tongue weight not to exceed 400 lbs./181 kg)
1500 lbs. (680 kg) on level ground
1995 lbs. (905 kg)
Overall Length
Overall Width
Overall Height
Wheelbase
Ground Clearance
Minimum Turning Radius
93.25 in. (237 cm)
47.6 in. (121 cm)
49.5 in. (125.7 cm)
57 in. (145 cm)
11.6 in. (29.5 cm)
96 in. (244 cm) unloaded
82 in. (208 cm) (in TURF mode)
Engine
Displacement
Bore x Stroke
Alternator Output
Compression Ratio
Starting System
Ignition System
Idle RPM**
Ignition Timing
Spark Plug / Gap
Lubrication System
Driving System Type
Front Suspension
Rear Suspension
ES550PLE
549.7 cc
96.6 x 75
490w @ 1350 RPM/Peak 630w
9.6:1
Electric
Electronic Fuel Injection
1750 +/- 50
13 +/- 3 BTDC @ 1350 RPM, Engine warm
NGK BKR6E / .035 in. (0.9 mm)
Wet Sump
Automatic PVT (POLARIS Variable Transmission)
Dual A-Arm with 9" (22.9 cm) travel
Progressive rate with 10.25" (26 cm) travel
* Based on EU Directive 76/432/EC
**A higher initial idle speed of 1800 RPM will occur for the first few minutes of operation.
128
Transmission
Gear Reduction, Low
Gear Reduction, Reverse
Gear Reduction, High
Drive Ratio, Front
Tires/Pressure, Front
Tires/Pressure, Rear
Brakes, Front/Rear
Brake, Auxiliary
Brake, Parking
Headlight
SPECIFICATIONS
Sportsman 550 X2
H/L/N/R/P
5.034:1
4.508:1
2.693:1
3.818:1
26 x 8 - 14 / 7 psi (48.3 kPa)
26 x 10 - 14 / 5 psi (34.5 kPa)
Single-Control Hydraulic Disc, All-Wheel
Foot-Activated Hydraulic Disc, Rear Wheel
Hydraulic lock, all wheel
1 Single Beam on Headlight Pod (50 watt)
2 Single Beam on Bumper (50 watt)
8.26 watts
27 watts
Digital/Analog
Taillights
Brake Light
Instrument Cluster
Clutching
Altitude Shift
Weight
Drive Clutch
Spring
Meters
(Feet)
0-1800
(0-6000)
1800-3700
(6000-12000)
23-58
PN 1322911
23-54
PN 1322914
Red/Black
PN 7043500
Red/Black
PN 7043500
*EBS models require no helix/spring adjustment
Driven
Clutch
Spring
Red/White
PN 3235088
Red/White
PN 3235088
Helix*
105-165 BA3
PN 3235092
105-165 BA3
PN 3235092
129
DECLARATION OF CONFORMITY
Polaris Industries Inc.,
2100 Hwy 55, Medina, MN 55340 U.S.A.
Telephone 763-542-0500
April 22, 2010
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
___KA05__ / ___KA09__
___FA09__
___VA17__
___PB20__
___BA32__, ___NA32__
___CA32__, ___EA32__
___BA50__, ___BG50__
___GJ45__
___GJ52__, ___GP52__
___LH46__
___MH50__
___DH50__
___ZN55__ ___ZX55__
___TN55__, ___TX55__
___DN55__, ___DX55__
___MN76__
___CL76__, ___CF76__
___ZN85__, ___ZX85__
___TN85__, ___TX85__
___DN85__, ___DX85__
___RH45__
___RH50__
___TH76__
___WH50__
___WH76__
___HR76__
___HY76__, ___TY76__
___TH90__
___WH90__
___VH76__, ___VY76__
___XH76__
PRODUCT IDENTIFICATION
VEHICLE SERIES TRADE NAME
OUTLAW 50 / 90
SPORTSMAN 90
RZR 170
PHOENIX 200
TRAIL BLAZER 330
TRAIL BOSS 330
SCRAMBLER 500
OUTLAW 450
OUTLAW 525 / 525 S
SPORTSMAN 400
SPORTSMAN 500 HO
SPORTSMAN 500 HO TOURING
SPORTSMAN 550 EFI
SPORTSMAN 550 X2
SPORTSMAN 550 TOURING
SPORTSMAN 800
SPORTSMAN 800 6X6
SPORTSMAN 850 EFI
SPORTSMAN 850 X2
SPORTSMAN 850 TOURING
RANGER 400 / 450
RANGER 500 4X4
RANGER 800 EFI 4X4
RANGER 500 CREW
RANGER 800 EFI CREW
RANGER 800 6X6
RANGER HD 800 4X4
RANGER DIESEL
RANGER DIESEL CREW
RANGER RZR / RZR S
RANGER RZR 4
European Community Person
Authorized to Compile the Technical File:
Ross Clifford, General Manager
POLARIS Britain Ltd
Forge Mills Park, Station Road
Coleshill, Warwickshire B46 1HT
MODEL YEARS
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2008, 2009, 2010, 2011
2010, 2011
2009, 2010, 2011
2010, 2011
2010, 2011
2008, 2009, 2010, 2011
2009, 2010, 2011
2009, 2010, 2011
2010, 2011
2010, 2011
2010, 2011
2010, 2011
2010, 2011
2011
2010, 2011
2010, 2011
2010, 2011
2011
2011
2008, 2009, 2010, 2011
2011
Authorized Manufacturer Signatory
Empowered to Draw up the EC Declaration of
Conformity:
Lawrence E. Keller, Product Compliance Manager
7290 East Viking Blvd.
Wyoming, MN 55092
130
WARRANTY
LIMITED WARRANTY
POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH
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 vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
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 SIX
MONTH 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
TECHNICIAN SERVICE PERFORMED / COMMENTS
136
MAINTENANCE LOG
DATE MILES (KM)
OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
137
INDEX
0-9
4X4 Switch . . . . . . . . . . . . . . . . . . . 22
A
Accessories . . . . . . . . . . . . . . . . . . 118
Active Descent Control Fluid . . . 84-85
Active Descent Control System. . . . 34
ADC System . . . . . . . . . . . . . . . . . . 34
Age Restrictions. . . . . . . . . . . . . . . . . 6
Air Filter . . . . . . . . . . . . . . . . . . . . . 96
All Wheel Drive System . . . . . . . 32-33
Auxiliary Foot Brake . . . . . . . . . . . . 91
B
Battery . . . . . . . . . . . . . . . . . . 109-113
Charging . . . . . . . . . . . . . 112-113
Installation . . . . . . . . . . . . . . . 110
Removal. . . . . . . . . . . . . . . . . 109
Storage . . . . . . . . . . . . . . . . . . 111
Belt Life . . . . . . . . . . . . . . . . . . . . . . 30
Boots . . . . . . . . . . . . . . . . . . . . . . . . 17
Box, Front . . . . . . . . . . . . . . . . . . . . 37
Box/Compartment, Front. . . . . . . . . 37
Brake Fluid, Auxiliary Foot Brake . 29
Brake Fluid, Main Brake System. . . 27
Brake Lever . . . . . . . . . . . . . . . . . . . 26
Brake, Foot . . . . . . . . . . . . . . . . 29, 91
Brake, Hand Lever. . . . . . . . . . . . . . 91
Brake, Parking . . . . . . . . . . . . . . . . . 28
Brakelight Lamp Replacement . . . 101
Brakes . . . . . . . . . . . . . . . . . . . . . . . 91
Break-In Period . . . . . . . . . . . . . . . . 48
C
Camber Adjustment . . . . . . . . . . . . 117
Cargo . . . . . . . . . . . . . . . . . . . . . . 67-69
Cargo Loading . . . . . . . . . . . . . . . . . 66
Caster Adjustment . . . . . . . . . . . . . 117
Check Engine Indicator . . . . . . . . . . 45
Cleaning and Storage. . . . . . . . 119-122
Clothing . . . . . . . . . . . . . . . . . . . . . . 17
Clutching . . . . . . . . . . . . . . . . . . . . 129
Cold Weather Operation . . . . . . . . . 51
Coolant Bottle . . . . . . . . . . . . . . . . . 89
Coolant, Radiator. . . . . . . . . . . . . . . 90
Cooling System . . . . . . . . . . . . . . 88-90
D
Demand Drive Fluid . . . . . . . . . . 82-83
Diagnostic Codes. . . . . . . . . . . . . . . . 47
Disengaging Active Descent Control 34
Display Units, Standard/Metric . . . . . 42
Drive Belt Wear/Burn . . . . . . . . . . . 123
Drivetrain Break-In . . . . . . . . . . . . . . 48
Driving Downhill. . . . . . . . . . . . . . . . 59
Driving in Reverse. . . . . . . . . . . . . . . 64
Driving on a Sidehill . . . . . . . . . . . . . 58
Driving on Slippery Surfaces . . . . . . 56
Driving Over Obstacles . . . . . . . . . . . 63
Driving Procedures . . . . . . . . . . . . . . 52
Driving Through Water . . . . . . . . . . . 62
Driving Uphill . . . . . . . . . . . . . . . . . . 57
Driving with a Passenger. . . . . . . 54-55
E
Electromagnetic Interference. . . . . . . 70
Electronic Throttle Control . . . . . . . . 25
Engaging 4X4 . . . . . . . . . . . . . . . . . . 33
Engaging Active Descent Control . . . 34
Engine Break-In. . . . . . . . . . . . . . . . . 48
Engine Fogging . . . . . . . . . . . . . . . . 122
Engine Oil . . . . . . . . . . . . . . . . . . 76-79
Engine Stop Switch . . . . . . . . . . . . . . 23
Equipment Modifications . . . . . . . . . . 7
Error Codes, Engine . . . . . . . . . . . . . 45
Exhaust Emission Control System . . 70
Eye Protection . . . . . . . . . . . . . . . . . . 17
F
Fluid
ADC. . . . . . . . . . . . . . . . . . . 84-85
Brake . . . . . . . . . . . . . . . . . . . . . 27
Coolant . . . . . . . . . . . . . . . . . . . 88
Demand Drive . . . . . . . . . . . 82-83
Engine Oil . . . . . . . . . . . . . . . . . 76
Rear Gearcase . . . . . . . . . . . . . . 86
Recommended Lubricants . . . . . 75
Transmission . . . . . . . . . . . . . . . 80
Fluid Change
ADC. . . . . . . . . . . . . . . . . . . . . . 85
Demand Drive . . . . . . . . . . . . . . 83
Engine Oil . . . . . . . . . . . . . . 78-79
Rear Gearcase . . . . . . . . . . . . . . 87
Transmission Oil . . . . . . . . . . . . 81
138
F
Fluid Level
ADC . . . . . . . . . . . . . . . . . . . . . 84
Brake. . . . . . . . . . . . . . . . . . 27, 29
Coolant Bottle . . . . . . . . . . . . . . 89
Demand Drive. . . . . . . . . . . . . . 83
Engine Oil . . . . . . . . . . . . . . . . . 77
Radiator. . . . . . . . . . . . . . . . . . . 90
Rear Gearcase . . . . . . . . . . . . . . 86
Transmission Oil. . . . . . . . . . . . 80
Foot Brake, Auxiliary . . . . . . . . . . . . 29
Footwell Removal. . . . . . . . . . . . . . . 93
Front Box/Compartment . . . . . . . . . . 37
Front Gearcase (Demand Drive). 82-83
Fuel Recommendations. . . . . . . . . . . 31
Fuel Safety . . . . . . . . . . . . . . . . . . . . 15
Fuel Tank Cap. . . . . . . . . . . . . . . . . . 31
Fuse Replacement . . . . . . . . . . . . . . . 97
G
Gasoline Handling . . . . . . . . . . . . . . 15
Gauge, Code Definitions. . . . . . . 46-47
Gauge, Digital/Analog . . . . . . . . 38-45
Gear Selector. . . . . . . . . . . . . . . . . . . 30
Gearcase Oil, Rear . . . . . . . . . . . 86-87
Gloves . . . . . . . . . . . . . . . . . . . . . . . . 17
H
Hand Brake . . . . . . . . . . . . . . . . . . . . 91
Handlebar Adjustment . . . . . . . . . . 116
Hauling Cargo. . . . . . . . . . . . . . . 66-69
Hazard Switch. . . . . . . . . . . . . . . . . . 23
Headlight Housing Replacement . . 100
Headlight Lamp Replacement . . . . . 98
Headlight Switch. . . . . . . . . . . . . . . . 24
Helmet. . . . . . . . . . . . . . . . . . . . . . . . 16
High Beam Adjustment . . . . . . . . . . 99
High Range Use . . . . . . . . . . . . . . . 108
Horn Switch . . . . . . . . . . . . . . . . . . . 23
Hub Tightening . . . . . . . . . . . . . . . . . 94
I
Idle RPM Adjustment . . . . . . . . . . . 114
Immersion Maintenance . . . . . . . . . 104
Indicator Lamps . . . . . . . . . . . . . . . . 39
Instrument Cluster. . . . . . . . . . . . 38-47
INDEX
K
Key Switch . . . . . . . . . . . . . . . . . . . . 22
K-Turn . . . . . . . . . . . . . . . . . . . . 60-61
L
Lights . . . . . . . . . . . . . . . . . . . . 98-101
Headlight Housing . . . . . . . . . 100
Headlight Lamp . . . . . . . . . . . . 98
High Beam Adjustment . . . . . . 99
Low Beam Adjustment . . . . . . 100
Lower Headlamp Replacement 101
Taillight/Brakelight. . . . . . . . . 101
Turn Signal Replacement . . . . 100
Low Beam Adjustment . . . . . . . . . . 100
Low Range Use. . . . . . . . . . . . . . . . 108
Lower Headlamp Replacement. . . . 101
Lubrication Guide. . . . . . . . . . . . . . . 75
M
Maintenance Chart . . . . . . . . . . . 71-74
Master Cylinder . . . . . . . . . . . . . . . . 27
Metric Display . . . . . . . . . . . . . . . . . 42
Mirrors . . . . . . . . . . . . . . . . . . . . . . . 25
MODE Button. . . . . . . . . . . . . . . . . . 24
Modifications . . . . . . . . . . . . . . . . . . . 7
Momentary High-Beam Switch . . . . 23
N
Noise Emission Control System . . . . 70
O
Oil
Engine . . . . . . . . . . . . . . . . . 76-79
Rear Gearcase . . . . . . . . . . . 86-87
Transmission. . . . . . . . . . . . 80-81
Oil Change
Engine . . . . . . . . . . . . . . . . 78-79
Rear Gearcase . . . . . . . . . . . . . . 87
Transmission. . . . . . . . . . . . . . . 81
Oil Level
Engine . . . . . . . . . . . . . . . . . . . . 77
Rear Gearcase . . . . . . . . . . . . . . 86
Transmission. . . . . . . . . . . . . . . 80
Oil Recommendations . . . . . . . . . . . 76
Override Switch . . . . . . . . . . . . . . . . 24
139
INDEX
P
Parking Brake . . . . . . . . . . . . . . . . . 28
Parking on an Incline . . . . . . . . . . . . 65
Passenger Seat . . . . . . . . . . . . . . 35, 36
Periodic Maintenance Chart . . . . 71-74
Polaris Product List . . . . . . . . . . . . 127
Polishing the Vehicle. . . . . . . . . . . 120
Pre-Ride Checklist . . . . . . . . . . . . . . 49
PVT Break-In. . . . . . . . . . . . . . . . . . 48
PVT Drying . . . . . . . . . . . . . . . . . . 108
PVT System. . . . . . . . . . . . . . . 106-108
R
Reverse Operation . . . . . . . . . . . . . . 64
Rider Information Center. . . . . . . 40-45
Rider Safety . . . . . . . . . . . . . . . . . . 8-15
Riding Gear . . . . . . . . . . . . . . . . . 16-17
S
Safe Operation Practices . . . . . . . . . 50
Safety Labels . . . . . . . . . . . . . . . . 18-21
Safety Training . . . . . . . . . . . . . . . . . 6
Seat Removal . . . . . . . . . . . . . . . . . . 93
Severe Use . . . . . . . . . . . . . . . . . . . . 71
Side Panel Removal. . . . . . . . . . . . . 93
Sidehilling . . . . . . . . . . . . . . . . . . . . 58
Signal Words . . . . . . . . . . . . . . . . . . . 4
Spark Arrestor . . . . . . . . . . . . . . . . 105
Spark Arrestor Requirements . . . . . 70
Spark Plug Inspection . . . . . . . 102-103
Spark Plug Recommendations. . . . 102
Spark Plugs . . . . . . . . . . . . . . . 102-103
Speedometer . . . . . . . . . . . . . . . . . . 38
Spring Adjustment, Shock . . . . . . . 117
Starting the Engine . . . . . . . . . . . . . 51
Steering Assembly . . . . . . . . . . . . . . 92
Steering Lock. . . . . . . . . . . . . . . . . . 31
Stop Switch . . . . . . . . . . . . . . . . . . . 23
Storage . . . . . . . . . . . . . . . . . . . 119-122
Storage Tips . . . . . . . . . . . . . . . 121-122
S
Switches . . . . . . . . . . . . . . . . . . . 22-24
4X4 Switch . . . . . . . . . . . . . . . . 22
Engine Stop Switch . . . . . . . . . . 23
Hazard Switch . . . . . . . . . . . . . . 23
Headlight Switch . . . . . . . . . . . . 24
Horn Switch. . . . . . . . . . . . . . . . 23
Main Key Switch . . . . . . . . . . . . 22
MODE Button . . . . . . . . . . . . . . 24
Momentary High-Beam Switch 23
Override Switch. . . . . . . . . . . . . 24
Turn Signal Switch . . . . . . . . . . 23
T
Taillight Lamp Replacement . . . . . . 101
Throttle Body Adjustment . . . . . . . . 114
Throttle Cable Freeplay Adjustment . . .
114, 115
Throttle Lever . . . . . . . . . . . . . . . . . . 25
Tire Tread Depth . . . . . . . . . . . . . . . . 94
Tires . . . . . . . . . . . . . . . . . . . . . . 94-95
Wheel Installation . . . . . . . . . . . 95
Wheel Nut Torque . . . . . . . . . . . 95
Wheel Removal . . . . . . . . . . . . . 94
Toe Alignment. . . . . . . . . . . . . . . . . . 92
Towing Capacities . . . . . . . . . . . . . . . 68
Towing Loads . . . . . . . . . . . . . . . . . . 68
Training, Safety . . . . . . . . . . . . . . . . . . 6
Transmission . . . . . . . . . . . . . . . . . . . 30
Transmission Oil . . . . . . . . . . . . . 80-81
Transporting the Vehicle . . . . . . . . . 118
Turn Signal Lamp Replacement . . . 100
Turn Signal Switch . . . . . . . . . . . . . . 23
Turning Around on a Hill . . . . . . 60-61
Turning the Vehicle . . . . . . . . . . . . . . 53
V
Vehicle Identification Numbers. . . . . . 5
Vehicle Immersion . . . . . . . . . . . . . 104
VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
W
Warning Symbols . . . . . . . . . . . . . . . . 4
Washing the Vehicle . . . . . . . . 119-120
Wheel Installation . . . . . . . . . . . . . . . 95
Wheel Nut Torque Specifications . . . 95
Wheel Removal . . . . . . . . . . . . . . . . . 94
140
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Table of contents
- 3 WELCOME
- 5 TABLE OF CONTENTS
- 7 INTRODUCTION
- 8 Vehicle Identification Numbers
- 8 SAFETY
- 8 Safety Training
- 8 Age Restrictions
- 9 Restrictions
- 9 Equipment Modifications
- 11 Rider Safety
- 19 Safe Riding Gear
- 20 Safety Labels and Locations
- 24 FEATURES AND CONTROLS
- 24 Switches
- 27 Mirrors
- 28 Throttle Lever
- 29 Brake Lever
- 30 Master Cylinder/Brake Fluid
- 30 Parking Brake
- 32 Auxiliary Foot Brake
- 33 Automatic Transmission Gear Selector
- 34 Fuel Tank Cap
- 34 Steering Lock
- 35 All Wheel Drive System
- 37 Active Descent Control (ADC) System
- 38 Passenger Seat
- 40 Front Box/Compartment
- 40 Instrument Cluster
- 50 OPERATION
- 50 Break-In Period
- 51 Pre-Ride Checklist
- 52 Safe Operation Practices
- 53 Starting the Engine
- 54 Driving Procedures
- 55 Turning the Vehicle
- 56 Driving with a Passenger
- 58 Driving on Slippery Surfaces
- 59 Driving Uphill
- 61 Driving on a Sidehill
- 61 Driving Downhill
- 62 Turning Around on a Hill
- 64 Driving Through Water
- 65 Driving Over Obstacles
- 66 Driving in Reverse
- 67 Parking on an Incline
- 68 Hauling Cargo
- 72 EMISSION CONTROL SYSTEMS
- 73 Noise Emission Control System
- 73 Spark Arrestor
- 73 Exhaust Emission Control System
- 73 Electromagnetic Interference
- 74 MAINTENANCE
- 74 Periodic Maintenance Chart
- 77 Lubrication Guide
- 78 Engine Oil
- 82 Transmission Oil
- 84 Front Gearcase (Demand Drive) Fluid
- 87 Active Descent Control (ADC) Fluid
- 88 Rear Gearcase Oil
- 90 Cooling System
- 93 Brakes
- 95 Toe Alignment
- 96 Steering Assembly
- 96 Seat Removal
- 96 Side Panel/Footwell Removal
- 97 Tires
- 99 Air Filter
- 100 Fuse Replacement
- 101 Lights
- 105 Spark Plugs
- 107 Vehicle Immersion
- 108 Spark Arrestor
- 109 PVT System
- 111 Battery
- 116 Throttle Body/Idle RPM
- 116 Throttle Cable Freeplay
- 119 Handlebars
- 120 Front and Rear Springs
- 121 Transporting the Vehicle
- 121 Accessories
- 122 Cleaning and Storage
- 125 TROUBLESHOOTING
- 129 POLARIS PRODUCTS
- 130 SPECIFICATIONS
- 132 DECLARATION OF CONFORMITY
- 134 WARRANTY
- 137 MAINTENANCE LOG
- 140 INDEX