Polaris Sportsman 450, 570, Touring Owner' s Manual PDF

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Summary of Content for Polaris Sportsman 450, 570, Touring Owner' s Manual PDF

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.

Sportsman 450 HO Sportsman 570

Sportsman 570 EPS Sportsman 570 SP

Sportsman Touring 570 EPS Sportsman UTE 570

Owner's Manual for Maintenance and Safety

2016

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2016 Owners Manual Sportsman 450 HO 2X4

Sportsman 450 HO Sportsman 450 HO Zugmachine

Sportsman 570 Sportsman 570 EPS

Sportsman 570 EPS Zugmachine Sportsman 570 SP

Sportsman Touring 570 Sportsman Touring 570 EPS

Sportsman UTE 570

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POLARIS and SPORTSMAN are trademarks of POLARIS Industries Inc. Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. P/N 9926545

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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Features and Controls . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Emission Control Systems . . . . . . . . . . . . . . . 87 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 140 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 144 POLARIS Products. . . . . . . . . . . . . . . . . . . . . 152 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 157 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

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INTRODUCTION Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.

Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service Dealer (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.

Snowmobiles RZR sport vehicles All-terrain vehicles (ATVs) GEM electric vehicles Low emission vehicles (LEVs) VICTORY motorcycles RANGER utility vehicles INDIAN motorcycles BRUTUS work vehicles POLARIS POWER generators SLINGSHOT three wheel

motorcycles POLARIS DEFENSE combat

vehicles

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

The safety alert symbol indicates a potential personal injury hazard.

DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.

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

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

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

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

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

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INTRODUCTION Declaration of Conformity

Polaris Sales Europe Srl Routede IEtraz Business Center A5 1180 Rolle, Switzerland Telephone +41213-218-700

DECLARATION OF CONFORMITY September 21, 2015 Polaris Sales Europe Srl declares that the vehicle(s) listed below conform to the essential requirements applicable to all terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS

2006/42/EC as amended (Machinery Directive)

EN 15997

2004/108/EC as amended (EMC Directive)

97/24/EC Chapter 8

MODEL COMMERCIAL NAME SERIAL NUMBER

A_ _S_ _ 57_ _ (All combinations)

Sportsman 450 HO Sportsman 450 HO 2X4

Sportsman 570 Sportsman 570 EPS Sportsman 570 SP

TAPS_ _57_G_ _ _ _ _ _ _ (All combinations)

A_ _SU _ 57_ _ (All combinations)

Sportsman UTE 570 TAPS_ _57_G_ _ _ _ _ _ _ (All combinations)

A_ _SD _ 57_ _ (All combinations)

Sportsman Touring 570 Sportsman Touring 570 EPS

TAPS_ _57_G_ _ _ _ _ _ _ (All combinations)

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INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

Engine Serial Number

Key Number

VIN (front or rear frame) ####

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SAFETY

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 Never operate this vehicle without proper instruction. Take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.

Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on a 2-up ATV.

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

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

WARNING

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SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. 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. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label. Eye Protection: Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding 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.

E4

051039 0006.31

Helmet Eye

Protection

Gloves

Over-the-Ankle Boots

Long Pants

Long Sleeves

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SAFETY Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owners manual. See the OPERATION section of the owners manual for proper operating procedures.

Operating Without Instruction Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle. Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course

Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on a 2-up ATV. Even though a child may be within the recommended age group for operating some ATVs, he/she may not have the skills, abilities, or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury.

Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating an ATV.

WARNING

< 16

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SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield).

Carrying a Passenger Carrying a passenger on a 1-up ATV greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or rollover. Never carry a passenger on a 1-up ATV. Do not carry a passenger on a 2-up ATV until you have at least two hours of driving experience with the vehicle. See page 59.

Carrying More Than One Passenger on a 2-Up ATV Carrying more than one passenger on a 2-up ATV greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or rollover. Never carry more than one passenger on a 2-up ATV.

Operating on Public Roads Operating an off-road vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate an off-road vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off- highway use). Zugmachine Models only: This vehicle is approved for on-road operation.

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SAFETY Safety Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel with the engine stopped, and outdoors or in a well ventilated

area. Do not smoke or allow open flames or sparks in or near the area where

refueling is performed or where gasoline is stored. Do not overfill the tank. Do not fill the tank neck. If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Failure to Inspect Before Operating Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition. Always follow all inspection and maintenance procedures and schedules described in the owner's manual.

Operating on Pavement Operating an off-road vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the off-road vehicle and could result in loss of control and accident or rollover. Most ATV tires are designed for off-road use. Avoid operating an off-road vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.

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SAFETY Safety Warnings Physical Control of the ATV Removing even one hand from the handlebars or one foot from the footrest can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury. Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. 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.

Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in the owner's manual. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts Attempting wheelies, jumps and other stunts increases the risk of an accident or rollover. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Improper Hill Climbing Improper hill climbing could cause loss of control or rollover. Always follow proper procedures for climbing hills as described in the owner's manual. See page 63. Always move the 4X4 switch to 4WDC (if equipped) before ascending or descending a hill. See page 39.

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SAFETY Safety Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling

down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 65.

Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. Always move the 4X4 switch to 4WDC (if equipped) before ascending or descending a hill. See page 39.

Always check the terrain carefully before descending a hill.

Shift your weight rearward. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the vehicle to lean

sharply to one side. Travel straight down the hill when possible.

Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 64. Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 66.

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SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. Always maintain a steady speed when

climbing a hill. Always move the 4X4 switch to 4WDC (if

equipped) before ascending or descending a hill. See page 39.

If all forward speed is lost: Lean forward to keep body weight uphill. A

passenger should also lean uphill. Apply the brakes. Lock the parking brake when fully stopped. Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator may dismount.

Turn the ATV around and remount, following the procedure described in the owner's manual. See page 66.

If the ATV begins rolling downhill: Keep operator and passenger body weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever

brake gradually. When fully stopped, apply the rear brake as well, and then lock the parking

brake. Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator may dismount.

Turn the ATV around and remount, following the procedure described in the owner's manual. See page 66.

Operating on Steep Hills Operating on excessively steep hills could cause a rollover. Never operate on hills too steep for the ATV or for your abilities. Never operate a 1-up ATV on hills steeper than 25. Never operate a 2-up ATV on hills steeper than 15.

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SAFETY Safety Warnings Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively rough, slippery or loose terrain. Always use extra caution on rough, slippery or loose terrain.

Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 69. Before shifting into reverse gear, always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.

Operating at Excessive Speeds Operating the ATV at excessive speeds increases the operator's risk of losing control. Never operate at excessive speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.

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SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating Over Obstacles Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 74.

Skidding or Sliding Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). On slippery surfaces such as ice or loose gravel, travel slowly and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.

Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.

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SAFETY Safety Warnings Operating Through Deep Water Operating the ATV through deep or fast- flowing water could cause the tires to float, causing loss of control or rollover. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 68): Travel slowly. Balance your weight carefully. Avoid sudden movements. Maintain a slow and steady forward

motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

Improper Cargo Loading Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident. Never exceed the stated load capacity for

this ATV. Cargo should be properly distributed and

securely attached. Reduce speed when carrying cargo or

pulling a trailer. Allow a greater distance for braking.

Always follow the instructions in the owner's manual for carrying cargo or pulling a trailer. See page 71.

Always follow the instructions in the owner's manual for operating with a passenger. See page 59.

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SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party. 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. ATV operators assume all risk associated with ice conditions on frozen bodies of water.

Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only unless your vehicle is approved for on-road operation. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of rollover and loss of control. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the ATV Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

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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.

Sportsman 450 HO/570 EPS Zugmachine Labels

Tire Pressure/Load Alert (7181541) TIRE PRESSURE IN kPa: FRONT 35 REAR 35 MAXIMUM WEIGHT CAPACITY 220 kg

Clutch Cover Alert (7181427) Keep body parts away from belt.

Rack Alert (7181584) DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 41 kg Rear 82 kg

7181427

41 kg 82 kg

7181584

34,5 kPakPa 34,5 kPa 7181541

< 220kg Rack Alert

Clutch Cover Alert

Tire Pressure/Load Alert

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SAFETY Safety Labels and Locations Sportsman 450 HO/570 EPS Zugmachine Labels

General Alert (7181539) Before you operate this vehicle, read the owners manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. NEVER carry a passenger. This vehicle is approved for onroad use.

Override Alert (7181544) 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.

4X4 (AWD) Alert (7181543) Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning.

Hill Operation Alert (7181426) Never operate this vehicle on HILLS steeper than 25.

General Alert

Hill Operation Alert

Override Alert

4X4 (AWD) Alert

7181543

SPEEDO REVERSE OVERRIDE

7181544

7181426

<16

7181539

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SAFETY Safety Labels and Locations Sportsman 450 HO/570 Labels

General Alert (7181537) Before you operate this vehicle, read the owners manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry a passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

Override Alert (7181544) 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.

4X4 Alert (4X4 models) (7181543) Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181426) Never operate this vehicle on HILLS steeper than 25.

7181426

7181537

<16

SPEEDO REVERSE OVERRIDE

7181544

General Alert Hill Operation Alert

Override Alert

4X4 (AWD) Alert

7181543

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SAFETY Safety Labels and Locations Sportsman 450 HO/570 Labels

Tire Pressure/Load Alert (7181541) TIRE PRESSURE IN kPa: FRONT 35 REAR 35 MAXIMUM WEIGHT CAPACITY 220 kg

Clutch Cover Alert (7181427) Keep body parts away from belt.

Rack Alert (7181584) DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 41 kg Rear 82 kg

Hitch Capacity Alert (7181580) TRAILER MAX WEIGHT: 557 kg ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 57 kg

7181427

34,5 kPakPa 34,5 kPa 7181541

< 220kg

557 kg

718158055 kg

Rack Alert

Hitch Capacity AlertClutch Cover Alert

Tire Pressure/Load Alert

41 kg 82 kg

7181584

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SAFETY Safety Labels and Locations Sportsman Touring 570 Labels

General Alert (7181538) Before you operate this vehicle, read the owners manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry more than one passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

Override Alert (7181544) 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.

4X4 (AWD) Alert (7181543) Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181536) Never operate this vehicle on HILLS steeper than 15.

SPEEDO REVERSE OVERRIDE

7181544

7181538

<16 15

7181536

General Alert Hill Operation Alert

Override Alert

4X4 (AWD) Alert

7181543

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SAFETY Safety Labels and Locations Sportsman Touring 570 Labels

Tire Pressure/Load Alert (7182176) TIRE PRESSURE IN kPa: FRONT 35 REAR 35 MAXIMUM WEIGHT CAPACITY 261 kg

Clutch Cover Alert (7181427) Keep body parts away from belt.

Rack Alert (7181584) DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 41 kg Rear 82 kg

Hitch Capacity Alert (7181580) TRAILER MAX WEIGHT: 557 kg ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 57 kg

7181427

41 kg 82 kg

7181584

35 kPakPa 35 kPa 7182176

< 261 kg

Rack Alert

Hitch Capacity Alert

Clutch Cover Alert Tire Pressure/Load Alert

557 kg

718158055 kg

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SAFETY Safety Labels and Locations SPORTSMAN UTE 570 Labels

General Alert (7181537) Before you operate this vehicle, read the owners manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry a passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

Override Alert (7181544) 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.

4X4 (AWD) Alert (7181543) Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181536) Never operate this vehicle on HILLS steeper than 15.

7181543

SPEEDO REVERSE OVERRIDE

7181544

General Alert

Hill Operation Alert

Override Alert

AWD Alert

15 7181536

7181537

<16

27

SAFETY Safety Labels and Locations SPORTSMAN UTE 570 Labels

Rack Alert (7182351) DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Max. Rack Load: Front 41 kg

Box Alert (7182312) Remove flammable material containers from box before filling. Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load: 181 kg

Hitch Capacity Alert (7181580) TRAILER MAX WEIGHT: 557 kg ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 57 kg

Tire Pressure Alert (7183262) TIRE PRESSURE IN kPa: FRONT 34.5 REAR 34.5 Read owners manual.

Clutch Cover Alert (7181427) Keep body parts away from belt.

Crush Alerts To prevent a crushing injury to hands and fingers, keep hands and fingers away from the lower front edge of the cargo box while lowering the box.

41 kg

7182351 7182312

< 181 kg

7181427

557 kg

718158055 kg

Hitch Capacity Alert

Rack Alert

Clutch Cover Alert

Tire Pressure Alert

Box Alert

kPa

7183262

34,5 kPa 34,5 kPa

Crush Alerts 7184130

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FEATURES AND CONTROLS Mirrors (if equipped) Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.

Switches

Main Key Switch Use the main key switch to start the engine. See page 57 for starting procedures.

Mode/Reverse Override Switch (if equipped) This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button. WARNING! Pressing the override button while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override button. The override switch is also used to toggle through the modes of the rider information center. See page 40. Tip: The override switch will not function as a MODE switch if the transmission

is in reverse.

4X4 Switch (if equipped) Use the 4X4 switch to engage 4WDC, 4X4 or 2X4. See page 39. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

Main Key Switch

4X4 Switch Work Light Switch (Zugmachine only)

Fog Light Switch (Zugmachine only)

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FEATURES AND CONTROLS Switches Engine Stop Switch The engine will not start or run when the switch is in the OFF position.

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.

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

High Beam

Low Beam Turn Signal Switch (if equipped)

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

Press the horn switch to sound the horn. Hazard Warning Switch

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

Engine Stop

SwitchHeadlight Switch

Horn Switch

Hazard Switch

Turn Signal Switch

Reverse Override Switch

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FEATURES AND CONTROLS Steering Lock (if equipped) 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. WARNING! The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

Throttle Lever WARNING! 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.

31

FEATURES AND CONTROLS Brake Lever

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

Squeeze the brake lever 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.

WARNING

32

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 ATV on a level

surface. 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.

4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

WARNING

Master Cylinder

Indicator Window

33

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. WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating. The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

34

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 seat on the left side of the vehicle. Maintain the fluid level between the maximum and minimum marks.

WARNING

Auxiliary Foot Brake

Foot Brake Fluid Reservoir

35

FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 41 for EPS Warning Indicator information.

Fuel Tank Cap This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition. Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface. Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 = (R + M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

Passenger Seat Backrest (Touring) The passenger backrest can be adjusted vertically. 1. Unzip the two zippers at the bottom

of the backrest pad. Lift the pad upward to remove it from the backrest frame.

2. To adjust the backrest upward or downward, loosen the four vertical adjustment screws on the front side of the backrest frame. Slide the backrest upward or downward to the desired position and tighten the screws.

3. Reinstall the backrest pad.

Fuel Tank Cap

36

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 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 ATV is left unattended, always place the transmission in PARK and lock the parking brake. Belt Life To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.

Extreme Use Battery An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, please see your POLARIS dealer. Ask your dealer to provide any installation procedures that may differ for an extreme use battery.

Gear Selector

37

FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the AWD momentary switch. Engage AWD before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. Move the momentary

switch to the right to engage AWD.

Move the momentary switch to the right, past the AWD setting, to engage 4WDC (if equipped).

Move the momentary switch to the far left to operate in two-wheel drive (2X4).

NOTICE: Switching to AWD or 4WDC (if equipped) while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD or 4WDC (if equipped) while the rear wheels have traction or are at rest.

AWD Switch

38

FEATURES AND CONTROLS All Wheel Drive System AWD Mode Move the momentary switch to the right to engage AWD (4X4). AWD will engage when engine speed slows to below 3100 RPM. The gauge will display AWD. There is no limit to the length of time the vehicle may remain in AWD. The vehicle automatically engages AWD when operating in reverse if the switch is set to the AWD position. Once enabled, AWD remains enabled until the switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction. When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

4WDC AWD Mode (if equipped) Move the momentary switch to the right, past the AWD setting, to engage 4WDC (if equipped). When the switch is on 4WDC, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to 4WDC (if equipped) before ascending or descending a hill. See page 39.

2X4 Mode Move the momentary switch to the far left to operate in two-wheel drive (2X4). AWD will disengage when engine speed slows to below 3100 RPM. The gauge will display 2X4.

39

FEATURES AND CONTROLS All Wheel Drive System Four-Wheel Descent Control (4WDC) System The 4WDC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to 4WDC (if equipped) before ascending or descending a hill.

Engaging Four-Wheel Descent Control The 4WDC system will automatically engage when all of the following conditions occur: The 4X4 switch must be in the 4WDC position The throttle must be closed (throttle lever released) The transmission must be in gear (high, low or reverse)

Disengaging Four-Wheel Descent Control The 4WDC system will automatically disengage if at least one of the following conditions occur: The 4X4 switch is moved out of the 4WDC position The throttle is open (throttle is applied) The transmission is shifted to neutral or park The vehicle is on flat ground, or not actively descending a hill

40

FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage ATV components. Wash the ATV

by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

Digital/Analog Gauge Speedometer The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).

Rider Information Center

SpeedometerIndicator Lamps

41

FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

Over Temperature

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

EPS Warning (if equipped)

This indicator illuminates when the key is turned to the ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service.

Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.

High Beam This lamp illuminates when the headlamp switch is set to high beam.

Check Engine This indicator appears if an EFI-related fault occurs. Do not operate the ATV if this warning appears. Serious engine damage could result. See your dealer.

42

FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 45.

Trip 1

km mi

RPM E F

88:88

1

2

3

567 4

43

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, programmable service hour interval and mode selection (when using the AWD momentary switch).

4. Four-Wheel Descent Control Display (if equipped) - This icon displays when 4WDC is active. See page 39.

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 45 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 45 for resetting instructions.

7. 4X4 Display - This icon displays when the 4X4 system is engaged (switch is on either 4WDC or 4X4).

44

FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.

Display Units (Standard/Metric) The display can be changed to display either standard or metric units of measurement. Tip: To exit the set-up mode at any time, wait 10 seconds. The display

automatically exits and returns to the odometer display.

1. Turn the key to the OFF position. 2. Place the transmission in neutral. 3. Press and hold the MODE button while turning the key to the ON

position. 4. When the display flashes the distance setting, tap the MODE button

to advance to the desired setting. 5. Press and hold the MODE button to save the setting and advance to

the next display option. 6. Repeat the procedure to change remaining display settings.

Standard Display Metric Display Distance Miles Kilometers Time 12-Hour Clock 24-Hour Clock

45

FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or

discharged. 1. Turn the key to the ON position. Use the MODE button to toggle to

the odometer display. 2. Press and hold the MODE button until the hour segment flashes.

Release the button. 3. With the segment flashing, tap the MODE button to advance to the

desired setting. 4. Press and hold the MODE button until the next segment flashes.

Release the button. 5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.

After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Odometer Mode The odometer records and displays the distance traveled by the ATV.

Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

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

46

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.

47

FEATURES AND CONTROLS Instrument Cluster Digital/Analog Gauge Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off. The code and message is lost, but will reappear if the fault reoccurs after restarting the engine. If the CHECK ENGINE light illuminates, retrieve the error codes from the display. Please see your Polaris dealer for all major repairs. 1. If the error codes are not displayed, use the MODE button to toggle

until Ck ENG displays on the main line of the display. 2. Press and hold the MODE button to enter the diagnostics code

menu. 3. Record the numbers displayed in the gear position (if any), clock

and odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See pages 48-50 for code definitions and failure descriptions. Please

see your Polaris dealer for all major repairs.

Error Code Number (0-9)

Suspect Parameter Number (SPN)

Failure Mode Indicator (FMI)

48

FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart. Shorted Load: The wires leading to the item listed in the chart are shorted together, or the item has shorted internally. Short-to-Battery: The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at battery voltage.

Diagnostic Codes Component Condition SPN FMI

Accelerator Position 2

Data Erratic, Intermittent Or Incorrect 29 2 Voltage Above Normal, Or Shorted To High Source 29 3 Voltage Below Normal, Or Shorted To Low Source 29 4

Throttle Position Sensor 1

Data Valid But Above Normal Operational Range - Most Severe Level

51 0

Data Valid But Below Normal Operational Range - Most Severe Level

51 1

Data Erratic, Intermittent Or Incorrect 51 2 Voltage Above Normal, Or Shorted To High Source 51 3 Voltage Below Normal, Or Shorted To Low Source 51 4 Abnormal Rate Of Change 51 10 Out Of Calibration 51 13

Vehicle Speed Sensor

Data Valid But Above Normal Operational Range - Most Severe Level

84 0

Data Valid But Below Normal Operational Range - Most Severe Level

84 1

Data Erratic, Intermittent Or Incorrect 84 2 Voltage Above Normal, Or Shorted To High Source 84 3 Voltage Below Normal, Or Shorted To Low Source 84 4 Abnormal Frequency Or Pulse Width Or Period 84 8 Abnormal Update Rate 84 9 Abnormal Rate Of Change 84 10 Bad Intelligent Device Or Component 84 12 Received Network Data In Error 84 19

Accelerator Position 1

Data Erratic, Intermittent Or Incorrect 91 2 Voltage Above Normal, Or Shorted To High Source 91 3 Voltage Below Normal, Or Shorted To Low Source 91 4

Manifold Absolute Pressure Sensor

Data Erratic, Intermittent Or Incorrect 102 2 Voltage Above Normal, Or Shorted To High Source 102 3 Voltage Below Normal, Or Shorted To Low Source 102 4 Mechanical System Not Responding Or Out Of Adjustment 102 7 Abnormal Rate Of Change 102 10

49

FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions

Diagnostic Codes Component Condition SPN FMI

Intake Air Temperature Sensor

Data Erratic, Intermittent Or Incorrect 105 2 Voltage Above Normal, Or Shorted To High Source 105 3 Voltage Below Normal, Or Shorted To Low Source 105 4 Abnormal Rate Of Change 105 10 Data Valid But Above Normal Operating Range - Least Severe Level

105 15

Engine Temperature Sensor

Data Valid But Above Normal Operational Range - Most Severe Level

110 0

Data Erratic, Intermittent Or Incorrect 110 2 Voltage Above Normal, Or Shorted To High Source 110 3 Voltage Below Normal, Or Shorted To Low Source 110 4 Abnormal Rate Of Change 110 10 Data Valid But Above Normal Operating Range - Least Severe Level

110 15

Data Valid But Above Normal Operating Range - Moderately Severe Level

110 16

Data Valid But Below Normal Operating Range - Least Severe Level

110 17

System Power Data Valid But Above Normal Operational Range - Most Severe Level

168 0

Data Valid But Below Normal Operational Range - Most Severe Level

168 1

Voltage Above Normal, Or Shorted To High Source 168 3 Voltage Below Normal, Or Shorted To Low Source 168 4 Data Valid But Above Normal Operating Range - Moderately Severe Level

168 16

Data Valid But Below Normal Operating Range - Moderately Severe Level

168 18

Engine Speed Data Valid But Above Normal Operational Range - Most Severe Level

190 0

Data Valid But Below Normal Operational Range - Most Severe Level

190 1

Data Erratic, Intermittent Or Incorrect 190 2 Mechanical System Not Responding Or Out Of Adjustment 190 7 Received Network Data In Error 190 19 Condition Exists 190 31

Gear Sensor Signal Data Erratic, Intermittent Or Incorrect 523 2 Voltage Above Normal, Or Shorted To High Source 523 3 Voltage Below Normal, Or Shorted To Low Source 523 4 Abnormal Update Rate 523 9

ECU Memory Bad Intelligent Device Or Component 628 12 Out Of Calibration 628 13

Calibration Out Of Calibration 630 13 Crankshaft Position Sensor

Data Erratic, Intermittent Or Incorrect 636 2 Abnormal Frequency Or Pulse Width Or Period 636 8

Injector 1 (Front) (MAG) (SDI Port Injector)

Voltage Above Normal, Or Shorted To High Source 651 3 Voltage Below Normal, Or Shorted To Low Source 651 4 Current Below Normal Or Open Circuit 651 5

50

FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions

Diagnostic Codes Component Condition SPN FMI

Fan Relay Driver Circuit

Voltage Above Normal, Or Shorted To High Source 1071 3 Voltage Below Normal, Or Shorted To Low Source 1071 4 Current Below Normal Or Open Circuit 1071 5

Ignition Coil Primary Driver 1 (Front) (MAG)

Voltage Above Normal, Or Shorted To High Source 1268 3 Voltage Below Normal, Or Shorted To Low Source 1268 4 Current Below Normal Or Open Circuit 1268 5

Fuel Pump Driver Circuit

Voltage Above Normal, Or Shorted To High Source 1347 3 Voltage Below Normal, Or Shorted To Low Source 1347 4 Current Below Normal Or Open Circuit 1347 5

Oxygen Sensor 1 Data Erratic, Intermittent Or Incorrect 3056 2 Voltage Above Normal, Or Shorted To High Source 3056 3 Voltage Below Normal, Or Shorted To Low Source 3056 4 Bad Intelligent Device Or Component 3056 12

ECU Output Supply Voltage 1

Data Valid But Above Normal Operational Range - Most Severe Level

3597 0

Data Valid But Below Normal Operational Range - Most Severe Level

3597 1

Voltage Above Normal, Or Shorted To High Source 3597 3 Voltage Below Normal, Or Shorted To Low Source 3597 4 Data Valid But Above Normal Operating Range - Moderately Severe Level

3597 16

Data Valid But Below Normal Operating Range - Moderately Severe Level

3597 18

ECU Output Supply Voltage 2

Data Valid But Above Normal Operational Range - Most Severe Level

3598 0

Data Valid But Below Normal Operational Range - Most Severe Level

3598 1

Voltage Above Normal, Or Shorted To High Source 3598 3 Voltage Below Normal, Or Shorted To Low Source 3598 4 Data Valid But Above Normal Operating Range - Moderately Severe Level

3598 16

Data Valid But Below Normal Operating Range - Moderately Severe Level

3598 18

ECU Output Supply Voltage 3

Data Valid But Above Normal Operational Range - Most Severe Level

3599 0

Data Valid But Below Normal Operational Range - Most Severe Level

3599 1

Voltage Above Normal, Or Shorted To High Source 3599 3 Voltage Below Normal, Or Shorted To Low Source 3599 4 Data Valid But Above Normal Operating Range - Moderately Severe Level

3599 16

Data Valid But Below Normal Operating Range - Moderately Severe Level

3599 18

ETC Accelerator Position Sensor Outputs 1 & 2 Correlation

Data Erratic, Intermittent Or Incorrect 65613 2

51

FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions

Diagnostic Codes Component Condition SPN FMI

Throttle Position Sensor 2 Data Valid But Above Normal Operational Range - Most Severe Level

520198 0

Data Valid But Below Normal Operational Range - Most Severe Level

520198 1

Data Erratic, Intermittent Or Incorrect 520198 2 Voltage Above Normal, Or Shorted To High Source 520198 3 Voltage Below Normal, Or Shorted To Low Source 520198 4 Abnormal Rate Of Change 520198 10 Out Of Calibration 520198 13

Active Descent Control System

Voltage Above Normal, Or Shorted To High Source 520203 3 Voltage Below Normal, Or Shorted To Low Source 520203 4 Current Below Normal Or Open Circuit 520203 5

Fuel Correction Front Data Valid But Above Normal Operating Range - Least Severe Level

520204 15

Data Valid But Below Normal Operating Range - Least Severe Level

520204 17

All Wheel Drive Control Circuit

Voltage Above Normal, Or Shorted To High Source 520207 3 Voltage Below Normal, Or Shorted To Low Source 520207 4 Current Below Normal Or Open Circuit 520207 5

Oxygen Sensor Heater 1 Data Erratic, Intermittent Or Incorrect 520209 2 Voltage Above Normal, Or Shorted To High Source 520209 3 Voltage Below Normal, Or Shorted To Low Source 520209 4 Current Below Normal Or Open Circuit 520209 5

Accelerator Position/Brake Position Interaction

Condition Exists 520275 31

Throttle Position Sensor (1 or 2 Indeterminable)

Data Erratic, Intermittent Or Incorrect 520276 2 Bad Intelligent Device Or Component 520276 12

Throttle Body Control - Power Stage

Data Erratic, Intermittent Or Incorrect 520277 2 Voltage Above Normal, Or Shorted To High Source 520277 3 Voltage Below Normal, Or Shorted To Low Source 520277 4 Abnormal Frequency Or Pulse Width Or Period 520277 8 Condition Exists 520277 31

Throttle Body Control - Return Spring Check Failed

Condition Exists 520278 31

Throttle Body Control - Adaption Aborted

Condition Exists 520279 31

Throttle Body Control - Limp Home Position Check Failed

Condition Exists 520280 31

Throttle Body Control - Mechanical Stop Adaptation Failure

Condition Exists 520281 31

Throttle Body Control - Repeated Adaptation Failed

Condition Exists 520282 31

Throttle Body Control Data Erratic, Intermittent Or Incorrect 520283 2 Voltage Above Normal, Or Shorted To High Source 520283 3 Voltage Below Normal, Or Shorted To Low Source 520283 4

52

FEATURES AND CONTROLS Instrument Cluster Diagnostic Display Code Definitions

Diagnostic Codes Component Condition SPN FMI

Throttle Body Control - Position Deviation Fault

Condition Exists 520284 31

ECU Monitoring Error Condition Exists 520286 31 ECU Monitoring Error (Level 3) Condition Exists 520287 31 ECU Monitoring of Injection Cut Off (Level 1)

Condition Exists 520288 31

ECU Monitoring of Injection Cut Off (Level 2)

Condition Exists 520289 31

Throttle Body Control - Requested Throttle Angle Not Plausible

Condition Exists 520305 31

ECU ADC Fault - No Load Condition Exists 520306 31 ECU ADC Fault - Voltage Condition Exists 520307 31 Accelerator Sensor Sync Fault - Sensor Diff Exceeds Limit

Condition Exists 520308 31

ECU Fault - ICO Condition Exists 520309 31 ECU Fault - Hardware Disruption Condition Exists 520311 31 Idle Fuel Correction Bank 1 Data Valid But Above Normal

Operating Range - Least Severe 520342 15

Data Valid But Below Normal Operating Range - Least Severe

520342 17

Adaptive Fuel Correction Bank 1 Data Valid But Above Normal Operating Range - Least Severe

520344 15

Data Valid But Below Normal Operating Range - Least Severe

520344 17

EPS Models Only Steering Over Current Shut Down Current Above Normal Or Grounded

Circuit 520221 6

Steering Excessive Current Error Current Above Normal Or Grounded Circuit

520222 6

Steering Torque Partial Failure Condition Exists 520223 31 Steering Torque Full Failure Condition Exists 520224 31 EPAS Inverter Temperature Data Valid But Above Normal

Operational Range - Most Severe 520225 0

Data Valid But Above Normal Operating Range - Severe

520225 16

EPAS Communications Receive Data Error

Data Erratic, Intermittent Or Incorrect 520226 2 Condition Exists 520226 31

Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or Component 520228 12 Condition Exists 520228 31

EPAS Software Error Bad Intelligent Device Or Component 520229 12 Condition Exists 520229 31

EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Voltage Error Voltage Above Normal, Or Shorted To

High Source 524086 3

Voltage Below Normal, Or Shorted To Low Source

524086 4

53

OPERATION

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

Break-In Period The break-in period for your new POLARIS ATV is the first 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.

Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 35. Always exercise

extreme caution whenever handling gasoline. 2. Check the oil level on the dipstick. See page 94. 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 56. 6. Pull only light loads. 7. Change both the oil and the filter at 25 hours. 8. Check fluid levels of transmission and all gearcases after the first 25

hours of operation and every 100 hours thereafter.

WARNING

54

OPERATION Break-In Period PVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. If a belt fails, always clean away all debris when replacing the belt.

Safe Operation Practices 1. Complete the recommended safety training before operating this

vehicle. See page 8. 2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

3. Never carry a passenger on a 1-up ATV. Never carry more than one passenger on a 2-up ATV.

4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.

5. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable).

6. Operate this vehicle off road only unless your vehicle is approved for on-road operation. Never operate an off-road vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

7. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

8. Drive in a manner appropriate for your skills, your passengers skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

9. Never consume alcohol or drugs before or while operating an ATV.

55

OPERATION Safe Operation Practices 10. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure. 11. Never operate a damaged ATV. After any rollover or accident, have

a qualified service dealer inspect the entire machine for possible damage.

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

13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

56

OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.

Item Remarks Page Brake system/lever travel Ensure proper operation 31

102 Brake fluid Ensure proper level 32 Auxiliary brake Ensure proper operation 34 Front suspension Inspect, lubricate if necessary 92 Rear suspension Inspect, lubricate if necessary 92 Steering Ensure free operation - Tires Inspect condition and pressure 107 Wheels/fasteners Inspect, ensure fastener tightness 107

108 Frame nuts, bolts, fasteners Inspect, ensure tightness - Fuel and oil Ensure proper levels 35

94 Coolant level (if applicable) Ensure proper level 100

101 Coolant hoses (if applicable) Inspect for leaks - Throttle Ensure proper operation 30 Indicator lights/switches Ensure operation 28, 40 Engine stop switch Ensure proper operation 29 Air filter, pre-filter Inspect, clean 109 Air box sediment tube Drain deposits whenever visible - Headlamp Check operation, apply POLARIS

dielectric grease when lamp is replaced

112

Brake light/taillight Check operation, apply POLARIS dielectric grease when lamp is replaced

117

Riding gear Wear approved helmet, goggles, and protective clothing

9

Winch (if equipped) Inspect cable and switch 75-86

57

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. 5. Do not press the throttle while starting the engine. 6. Turn the ignition key past the ON position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

7. 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 ATV 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.

58

OPERATION Driving Procedures

1. Wear a helmet and eye protection. See page 9. 2. Sit upright with both feet on the footrests and both hands on the

handlebars. 3. Start the engine and allow it to warm up. 4. Shift the transmission into gear. 5. Check your surroundings and determine your path of travel. 6. Release the parking brake. 7. Slowly depress the throttle with your right thumb and begin driving. 8. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

59

OPERATION Driving with a Passenger 1. Never carry a passenger on a 1-up ATV. Never carry more than one

passenger on a 2-up ATV. 2. Do not carry a passenger on a 2-up ATV until you have at least two

hours of driving experience with the vehicle. 3. Never allow anyone under 12 years of age to ride as a passenger on

a 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. Allow a passenger to ride only in the approved passenger seat.

4. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 9.

5. Perform the pre-ride inspection. See page 56.

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. Slow down. Control may be more difficult with a passenger on board. Allow more time and distance for braking.

60

OPERATION Driving with a Passenger 9. 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.

10. Do not cross a hillside with a passenger on board. See page 64. 11. 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. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

12. 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.

61

OPERATION Turning the Vehicle Your ATV is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly. 1. Slow down. 2. Never turn quickly when

carrying a passenger or cargo.

3. Steer in the direction of the turn.

4. Keep both feet on the footrests.

5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

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

WARNING! Turning improperly can result in vehicle rollover. Never turn abruptly or at sharp angles. Never turn at high speeds.

62

OPERATION Driving on Slippery Surfaces

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while

the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.

4. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids.

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

Turn in Direction of Skid

Sideways Skid

63

OPERATION Driving Uphill Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to 4WDC (if equipped) before

ascending or descending a hill. See page 39. 2. Drive straight uphill. 3. Avoid steep hills. Maximum

incline is: 15 (Touring/UTE) 25 (1-up Models)

4. Always check the terrain carefully before ascending any hill.

5. Never climb hills with excessively slippery or loose surfaces.

6. Keep both feet on the footrests. 7. Shift body weight uphill. A

passenger should also shift body weight uphill.

8. Proceed at a steady rate of speed and throttle opening. Opening the throttle suddenly could cause the ATV to flip over backwards.

9. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or another vehicle or person could be on the other side of the hill.

10. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

Touring/UTE 15 Maximum

1-Up ATVs 25 Maximum

64

OPERATION Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid crossing the side of a steep hill. 3. Do not cross a hillside with a passenger on board. Ask the passenger

to dismount and walk across the hillside before remounting the vehicle.

4. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

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

65

OPERATION Driving Downhill When driving downhill, follow these precautions: 1. Always move the 4X4 switch to 4WDC (if equipped) before

ascending or descending a hill. See page 39. 2. Avoid steep hills. Maximum

incline is: 15 (Touring/UTE) 25 (1-up Models)

3. Always check the terrain carefully before descending a hill.

4. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral.

5. Slow down. Never travel down a hill at high speed.

6. Drive straight downhill. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side.

7. Shift body weight uphill. A passenger should also shift body weight uphill.

8. Apply the brakes slightly to aid in slowing. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control.

Touring/UTE 15 Maximum

1-Up ATVs 25 Maximum

66

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)

67

OPERATION Turning Around on a Hill (K-Turn) 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to 4WDC (if equipped) before

ascending or descending a hill. See page 39. 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.

68

OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water

depths and current before entering water.

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

3. Avoid operating through deep or fast-flowing water. NOTICE: Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 88. The following areas need special attention: engine oil, transmission oil, demand drive fluid, rear gearcase oil, 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 120, then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.

If its unavoidable to enter water deeper than the footrest level: Proceed slowly. Avoid rocks and obstacles. Balance your weight carefully. Avoid sudden movements. Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

Maximum Depth

69

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. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. 7. Do not use the override button unless additional wheel speed is

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

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

70

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, which can result in serious injury or death. Always follow these precautions when hauling cargo: REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, 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 a cargo bed should be as far forward and as low as possible. 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 rollover. Always be sure that the cargo bed is lowered and latched before moving the vehicle. WEIGHT DISTRIBUTION on racks should be 1/3 on the front rack and 2/3 on the rear rack. Carrying loads on only one rack increases the possibility of vehicle rollover. 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. USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing vehicle rollover. 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 attach the tow load to the hitch point designated for your vehicle. USE EXTREME CAUTION when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 16 km/h while towing a load on a level surface. Vehicle speed should never exceed 8 km/h when towing loads in rough terrain, while cornering or while ascending or descending a hill. TOWING is approved OFF-ROAD ONLY unless your vehicle is approved for on- road operation.

WARNING

71

OPERATION Hauling Cargo 1. Never exceed the weight capacities

specified for your ATV on warning labels and in the specifications section of this manual.

2. On models with front and rear racks, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.

3. All Models: NEVER exceed 80 km/h when rear cargo loads are above 34 kg and/or front cargo loads are above 17 kg.

4. 2-Up Models: NEVER exceed 80 km/h while carrying a passenger.

5. UTE Models: NEVER exceed 16 km/h when rear cargo loads are above 91 kg. Make sure the cargo box dump latch is securely latched before loading and operating. Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured.

6. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.

7. Do not obstruct the headlight beam with cargo. 8. Use low forward gear when hauling or towing heavy cargo to

extend belt life. 9. Always operate the vehicle with extreme caution whenever hauling

or towing loads. Balance, handling, and control may be affected.

1/3 2/3

72

OPERATION Hauling Cargo Towing Loads Towing is approved OFF-ROAD ONLY unless your vehicle is approved for on-road operation. Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must

not exceed the rear rack capacity. The total load (operator, 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 ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.

Maximum 4" (10 cm)

73

OPERATION Hauling Cargo Dumping Cargo (UTE) WARNING! If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible. 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. 6. Pull one of the two

cargo box release levers upward.

7. Firmly grasp one of the cargo box handles and slowly lift the front of the cargo box to dump the cargo.

WARNING! To prevent a crushing injury to hands and fingers, keep hands and fingers away from the lower front edge of the cargo box while lowering the box. 8. Lower the cargo box and make sure the release latch is secured. 9. Secure the tailgate. WARNING! Driving 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 drive this vehicle with the cargo box in the raised position. Never leave this vehicle parked or unattended with the cargo box in the raised position.

Box Release Levers Handle

74

OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles: 1. Always check for

obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or fallen trees.

5. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.

Parking on an Incline Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in

PARK. 3. Lock the parking brake. 4. Always block the rear

wheels on the downhill side.

75

WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term winch cable will be used for either unless noted otherwise.

Winch Safety Precautions 1. Read all sections of this manual. 2. Never use alcohol or drugs before or while operating the winch. 3. Never allow children under 16 years of age to operate the winch. 4. Always wear eye protection and heavy gloves when operating the

winch. 5. Always keep body, hair, clothing and jewelry clear of the winch

cable, fairlead and hook when operating winch. 6. Never attempt to jerk a load attached to the winch with a moving

vehicle. See the Shock Loading section on page 84. 7. Always keep the area around the vehicle, winch, winch cable and

load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

10. Always apply your vehicles park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

WARNING

76

WINCH GUIDE Winch Safety Precautions 11. Always align the vehicle and winch with the load directly in front of

the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicles centerline whenever possible.

12. If winching at an angle is unavoidable, follow these precautions: A. Look at the winch drum occasionally. Never let the winch cable stack

or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 82 to feed and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winchs rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while winching a load.

17. Never let the winch cable run through your hands, even if wearing heavy gloves.

18. Never release the clutch on the winch when the winch cable is under load.

19. Never use the winch for lifting or transporting people.

77

WINCH GUIDE Winch Safety Precautions 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Take your winch

to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook fully into the winch. This can cause damage

to winch components. 24. Unplug the remote control from the vehicle when the winch is not in

use to prevent inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

78

WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique.

Take your time to think through the winching you are about to do. Proceed slowly and deliberately. Never hurry or rush during winching. Always pay attention to your surroundings. You may need to change your winching strategy if it is not working. Always remember that your winch is very powerful. There are simply some situations that you and your winch will not be able

to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable.

2. Never operate a winch or a vehicle in need of repair or service. 3. Always apply your vehicles

park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

WARNING

Hook Strap

79

WINCH GUIDE Winch Operation 4. Always use the hook strap when

handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY.

A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.

Tip: A tow strap is NOT intended to stretch. A recovery strap is designed to stretch.

WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 84.

B. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly (treadlightly.org).

E. Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.

F. Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.

NO YES

NOYES

80

WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winchs pulling

capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

8. Read and adhere to the following information for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cable

failure, always place a damper on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.

B. Lay the damper on top of the mid-point of the winch cable length that is spooled out.

C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.

D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

81

WINCH GUIDE Winch Operation 11. The ONLY time a winch-equipped vehicle should be moving when

using the winch is when that vehicle itself is stuck. The winch- equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 84. For your safety, always follow these guidelines when winching a vehicle free: A. Release the winch clutch and spool out the necessary length of winch

cable. B. Align the winch cable as close as possible to the winching vehicles

centerline. C. Attach the winch cable hook to the anchor point or the stuck vehicles

frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the

direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual. 12. Never attempt to winch another stuck vehicle by attaching the

winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.

82

WINCH GUIDE Winch Operation 13. Extensive winching will run down the battery on the winching

vehicle. Let the winching vehicles engine run while operating the winch to prevent the battery from running low if winching for long periods.

14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task. A. Release the clutch on the winch. B. Feed out the winch cable that is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 100 lbs. (45

kg) of tension using the hook strap. E. Slowly winch the cable in while your assistant moves the end of the

winch cable back and forth horizontally to evenly distribute the winch cable on the drum.

F. Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable.

83

WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY. 1. Always inspect your winch before each use. Inspect for worn or

loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A. A kinked winch cable made of

wire rope is shown at right. Even after being straightened out, this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

B. A kinked winch cable made of wire rope that has been straightened out is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.

C. A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.

D. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

A

B

C

84

WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or shock loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to jerk a load with the winch. For example, never

take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable. 2. Never quickly turn the winch ON and OFF repeatedly (jogging).

This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

85

WINCH GUIDE Shock Loading 4. Never use recovery straps with your winch. Recovery straps are

designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic bungie cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

86

WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.

87

EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

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

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

Electromagnetic Interference 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.

European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on many factors, including: Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature

88

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 157. 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.

89

MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key

WARNING! Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services.

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

D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering -

Pre-Ride

-

Make adjustments as need ed. See Pre-Ride Checklist on page 56.

Front suspension - - Rear suspension - - Tires - - Brake fluid level - - Brake lever travel - - Brake system - - Wheels/fasteners - - Frame fasteners - - Engine oil level - - Winch (if equipped) - - See pages 75-86 Air filter, pre-filter - Daily - Inspect; clean often; replace

as needed Air box sediment tube

- Daily - Drain deposits when visible

Coolant - Daily - Check level Power steering unit (if equipped)

- Daily - Inspect daily; clean often

Headlight/taillight/ worklight

- Daily - Check operation; apply dielectric grease if replacing lamps

90

MAINTENANCE Periodic Maintenance Chart

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Air filter, main element

- Weekly - Inspect; replace as needed

Recoil housing - Weekly - Drain water as needed, check often if operating in wet conditions

D Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test Fuel System 20 H Monthly - Inspect; cycle key to

pressurize fuel pump; check lines and fittings for leaks and abrasion

Engine breather valve (if equipped)

25 H Monthly 250 (400) Inspect; clean if needed

Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change Demand drive fluid (extreme use)

25 H 1 M 250 (400) Change fluid every 25 hours if 4WDC is subjected to extreme use. See page 99.

Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check Transmission oil 25 H 1 M 250 (400) Break-in oil level check General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,

cables, etc. Throttle Body Intake Duct

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as needed

Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength seasonally; pressure test system yearly

Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter Oil lines and fasteners

100 H 6 M 1000 (1600) Inspect for leaks and loose fittings

91

MAINTENANCE Periodic Maintenance Chart

Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval (whichever comes first)

Remarks

Hours Calendar Miles (Km)

Demand drive fluid (normal use)

100 H 12 M 1000 (1600) Change fluid; change fluid every 25 hours if ADC is subjected to extreme use. See page 99.

Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid Transmission oil 100 H 12 M 1000 (1600) Change fluid

D Fuel system/filter 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

Radiator (if applicable)

100 H 12 M 1000 (1600) Inspect; clean external surfaces

Cooling hoses (if applicable)

100 H 12 M 1000 (1600) Inspect for leaks

Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler/ pipe

100 H 12 M 1000 (1600) Inspect

D Spark plug 100 H 12 M 1000 (1600) Inspect; replace as needed Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

security; apply dielectric grease to connectors subjected to water, mud, etc.

D Clutches (drive and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn parts

D Front wheel bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

D Brake fluid 200 H 24 M 2000 (3200) Change every two years Spark arrester 300 H 36 M 3000 (4800) Clean out Coolant - 60 M - Replace coolant

D Valve clearance 500 H - 8000 (5000) Inspect; adjust Idle speed - Adjust as needed

D Toe adjustment - Inspect periodically; adjust when parts are replaced

Headlight aim - Adjust as needed

92

MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 88. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and lower control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Capacity at Fluid Change

Inspection Procedure

Engine Oil PS-4 5W-50 4-Cycle Oil

2 qt. (1.9 l) Maintain level in safe range on dipstick. See page 94.

Brake Fluid DOT 4 Brake Fluid --- Maintain level between fill lines. See page 32.

Transmission Oil AGL Gearcase Lubricant & Transmission Fluid

32 oz. (948 ml) Maintain level at bottom of fill hole threads. See page 97.

Demand Drive (Front Gearcase)

Demand Drive Fluid

9 oz. (265 ml) Maintain level at bottom of fill hole threads. See page 99.

Front Prop Shaft Yoke

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

Front Prop Shaft Yoke

93

MAINTENANCE Engine Oil Oil Recommendations

Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W- 50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 5W- 50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 152 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.

Lubricant Capacity Drain Plug Torque PS-4 5W-50 4-Cycle Oil 2 qts. (1.9 l) 14-17 ft-lbs (19-23 Nm)

94

MAINTENANCE Engine Oil Oil Level Access the oil dipstick and fill tube from the right side of the ATV. A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. 1. Position the vehicle on a level

surface. 2. Remove the dipstick. Wipe it

dry with a clean cloth. 3. Reinstall the dipstick

completely. 4. Remove the dipstick and

check the oil level. Maintain the oil level in the safe range. Do not overfill.

Safe Add Oil

Safe Range

Dipstick

Dipstick

95

MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 88. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level

surface. 2. Start the engine. Allow it to warm

up at idle for two to three minutes.

3. Stop the engine. 4. Clean the area around the drain

plug. 5. Place a drain pan under the crank

case. 6. Remove the drain plug. Allow the

oil to drain completely. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin. 7. Install a new sealing washer on

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

8. Reinstall the drain plug. Torque to 14-18 ft-lbs (19-24 Nm).

9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter- clockwise to remove it.

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

Oil Filter

Drain Plug

Front View of the Engine

Oil Filter

96

MAINTENANCE Engine Oil Oil and Filter Change 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 3/4 turn.

13. Remove the dipstick. 14. Add two quarts (1.9 l) of recommended oil. 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.

97

MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 88. Maintain the oil level at the bottom of the fill plug hole threads. See page 152 for the part numbers of POLARIS products. The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel. The drain plug is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well.

Transmission Oil Recommendations Lubricant Capacity Fill Plug

Torque Drain Plug

Torque AGL Gearcase Lubricant &

Transmission Fluid 32 oz.

(946 ml) 20-25 ft-lbs (27-34 Nm)

20-25 ft-lbs (27-34 Nm)

Drain PlugCheck/Fill Plug

98

MAINTENANCE Transmission Oil Oil Check 1. Position the vehicle on a level

surface. 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.

Oil Change 1. Remove the fill plug. 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. Add the proper amount of the recommended oil. 5. Reinstall the fill plug. Torque to specification. 6. Check for leaks. 7. Dispose of used oil properly.

Front Gearcase (Demand Drive) Fluid Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 88. Maintain the fluid level at the bottom of the fill hole threads. See page 152 for the part numbers of POLARIS products. Change the front gearcase fluid every 25 hours if the 4WDC unit is exposed to extreme use. Extreme use includes any of the following: operation in 4WDC mode for prolonged periods constant 4WDC operation on hilly or mountainous terrain 4WDC is the primary mode of all-wheel-drive operation Tip: If the front gearcase is makes excessive noise during 4WDC operation,

change the demand drive fluid. If the noise continues, please see your POLARIS dealer for service.

Fill LevelFill Plug

99

MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Recommendations

Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads. The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

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

the fluid level. 2. Add the recommended demand drive fluid as needed to bring the

level to the bottom of the fill hole threads. 3. Reinstall the fill plug. Torque to 8-10 ft-lbs (11-14 Nm).

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

drain pan under the demand drive unit. 2. Remove the drain plug. Allow the fluid to drain completely. 3. Clean and reinstall the drain plug. Torque to 11 ft-lbs (15 Nm). 4. Add the recommended fluid. See page 99 for capacity. Maintain the

fluid level at the bottom of the fill hole threads. 5. Reinstall the fill plug. Torque to 8-10 ft-lbs (11-14 Nm). 6. Check for leaks. Dispose of used fluid properly.

Gearcase Lubricant Capacity Fill Plug Torque

Drain Plug Torque

Front Gearcase

Demand Drive Fluid 9 oz. (265 ml)

8-10 ft-lbs (11-14 Nm)

11 ft-lbs (15 Nm)

Drain Plug

Fill Plug

Fill Level

100

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 Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 152 for the part numbers of POLARIS products.

Recovery Bottle Coolant The recovery bottle is located on the left side of the vehicle. 1. Remove the left side panel.

See page 105. 2. Maintain the coolant level

between the minimum and maximum marks on the bottle (when the fluid is cool).

3. Add coolant as needed. Recovery Bottle

101

MAINTENANCE Cooling System Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.

1. Open the front box cover.

2. Remove the access panel screws. Squeeze the outer edges of the panel inward to remove the panel.

3. Remove the pressure cap.

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

5. 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.

6. Reinstall the access panel and secure the front box cover.

Radiator Cap

102

MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill. WARNING! An over-full master cylinder may cause brake drag or brake lock- up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill. The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation. 1. Always keep brake fluid at an adequate

level. See page 32. 2. Check the brake system for fluid leaks. 3. Check the brakes for excessive travel or

spongy feel. 4. Check the friction pads for wear, damage

and looseness. Replace brake pads when they are worn to .030 (0.762 mm).

5. Check the security and surface condition of the disc. Clean any grease using a recommended brake cleaner or alcohol. Do not use spray lubricants or other petroleum-based products. If you discover any damage (cracks, excessive corrosion, warping) see your dealer for service before operating.

Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 34.

.030 (0.762 mm)

103

MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8 to 1/4 (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized POLARIS dealer.

1. Position the vehicle on a level surface.

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

3. Tie a length of string between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straight-edge instead of string.

4. Measure the distance from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 1/16-1/8 (2-3 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/8 to 1/4 (3-6 mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle. 6. If you discover improper alignment, see your POLARIS dealer for

service.

String

Stand

2

1

Front

104

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

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

Seat Removal 1. Grasp one side of the seat

near the rear edge. 2. Pull upward abruptly to

disengage the under-seat fasteners.

3. Remove the seat.

105

MAINTENANCE Side Panel Removal 1. Remove the seat. See page

104. 2. Use a flat screwdriver to

remove the plastic rivets securing the side panel.

3. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the side panel outward to disengage the side panel from the grommets.

4. Pull the panel outward and rearward to remove it.

Footwell Removal (1-Up Models) 1. Remove the four screws on

the bottom of the footwell. 2. Use a flat screwdriver to

remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

Step 2

Step 3

Torx Head Screws

Plastic Rivets

106

MAINTENANCE Footwell/Footwell Support Removal 1. Remove the six screws on the bottom of the footwell. 2. Use a flat screwdriver to remove the plastic rivets securing the

footwell to the fenders. 3. Remove the footwell. 4. If removing the footwell support is necessary to access the clutch

cover, remove the hex flange screw securing the support to the frame.

Torx Head Screws (6)

Plastic Rivets (4)

Footwell Support Hex Flange Screw

107

MAINTENANCE Tires

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 148 for recommended tire type, size and pressure.

Tire Tread Depth Always replace tires when tread depth is worn to 1/8 (3 mm) or less.

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

Wheel Removal 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Loosen the wheel nuts slightly. WARNING! 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.

WARNING

1/8 (3 mm)

108

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. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. Torque the wheel nuts to specification. WARNING! Loose nuts could cause a tire to come off during operation, which could result in an accident or rollover. Always ensure that all nuts are torqued to specification.

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

Nut Type Nut Torque

Lug Nut (Aluminum Wheels)

30 ft-lbs (41 Nm) PLUS 1/4 TURN

2-Piece Flange Nut (Steel Wheels)

27 ft. lbs. (37 Nm)

109

MAINTENANCE Air Filter 1. Remove the seat. 2. Release the air box cover

clips and remove the air box cover.

3. Loosen the clamp and remove the filter.

4. Remove the fabric type pre-filter from the main filter. Wash the pre-filter in soapy water, then rinse and let dry.

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

6. Reinstall the filter into the air box and tighten the clamp. Do not overtighten the clamp, as filter damage could occur.

7. Reinstall the air box cover and the seat.

Breather Line

Pre-Filter

Main Filter

Breather Valve

110

MAINTENANCE Breather Valve/Hose The breather valve is on the hose that runs between the engine and air box. See illustration on page 109. 1. Remove the left side panel. See page 105. 2. Remove the hose clamps from the valve and pull the valve out of

the hoses. 3. Inspect the valve for debris. Blow gently through the valve to check

for clogging. Replace a damaged or clogged valve. 4. Check the hoses for cracks, deterioration, abrasion, or leaks.

Replace as needed. 5. Reinstall the valve and hose clamps. NOTICE: Operation of your vehicle without a breather valve can cause engine

damage. Always reinstall the breather valve after removing it for service.

111

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 a compartment on the top of the access door. 1. Open the front box cover. 2. Remove the access panel.

See page 101. 3. Remove fuse box cover. 4. Remove the suspect fuse

from the fuse panel. If the fuse is blown, install a new fuse with the same amperage.

5. Secure the fuse box cover and access panel.

6. Secure the front box cover.

Fuse Box

Label inside the Fuse Box Cover

112

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.

High Beam Adjustment The headlight beam can be adjusted slightly. Use the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approximately 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.

x x

7.6 m

5 cmX X

7.6 m

5 cm

Models with pod headlight

Models without pod headlight

113

MAINTENANCE Lights High Beam Adjustment 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 5 cm below the mark on the wall. Include rider weight on the seat when measuring.

5. 570 SP: 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.

6. 570/570 EPS/UTE: The adjustment knob is located on the right side of the headlight pod. Adjust the beam to the desired position by turning the knob either clockwise or counter- clockwise.

7. 450 HO: Tighten or loosen the three (3) headlight screws to adjust the beam.

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.

570 SP Adjustment Screw

450 HO Screws

Phillips Screw

114

MAINTENANCE Lights Headlight Lamp Replacement When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. 1. 450 HO: 450 HO models do not have a pod headlight. See page 117

for lower headlamp replacement.

570 SP: Remove the seven (7) headlight pod screws. Pull the pod cover forward.

570/570 EPS/UTE: Remove the two screws on the lower front corners of the headlight pod. Remove the screw from the rear of the pod. Lift the pod slightly while depressing the tabs at the rear of the pod. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool before servicing. 2. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring. 3. Turn the lamp counter-clockwise to remove it. 4. Apply dielectric grease to the socket and install the new lamp. Make

sure the tab on the lamp locates properly in the housing. 5. Reassemble the pod.

115

MAINTENANCE Lights Headlight Housing Replacement (570/570 EPS/UTE) 1. Remove the two screws on the lower front corners of the headlight

pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer. 4. Unplug the headlamp from the wiring harness. 5. Use a small screwdriver to remove the o-rings from the headlight

mounting tabs. 6. Pull the headlight housing up to release it from the locking tabs. 7. Lift the adjusting knob up to remove it from the locking tabs. 8. Carefully pull the assembly up

and out of the pod. 9. Reverse the steps to install the

new housing and reassemble the pod. The distance from the headlamp parting line to the end of the adjustment knob stop is 5 1/8 (13 cm).

10. Adjust the headlight aim by turning the adjusting knob. 5 1/8

(13 cm)

116

MAINTENANCE Lights Headlight Housing Replacement (570 SP) 1. Remove the seven (7)

headlight pod screws. 2. Pull the pod cover

forward. 3. Unplug the headlamp

from the wiring harness.

4. Use a small screwdriver to remove the o-rings from the headlight mounting tabs.

5. Pull the headlight housing up from bracket for removal. 6. Reverse the steps to install the new housing and reassemble the pod.

Headlight Housing

117

MAINTENANCE Lights Lower Headlamp Replacement 1. Turn the back of the headlight

harness counter-clockwise and pull the harness assembly away from the headlight assembly.

2. Remove the headlamp and install the new headlamp.

3. Reinstall the harness assembly into the headlight assembly.

4. Turn the headlight harness clockwise to secure the headlamp.

Taillight/Brakelight Lamp Replacement 1. Remove the harness connector

from the back of the light assembly.

2. Turn the lamp counter-clockwise to remove it.

3. Apply dielectric grease to the socket and install the new lamp.

4. Reinstall the harness connector. 5. Test the light for proper

operation.

Harness

Lamp

Phillips Screw

Lamp

Harness Connector

Taillight

Socket

118

MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 148 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use POLARIS-recommended spark plugs.

Spark Plug Inspection Spark plug condition is indicative of engine operation. Check the spark plug firing end condition after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. See page 119. CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection. 1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug. 2. Using the special wrench provided in the tool pouch, rotate the

spark plug counter-clockwise to remove it. 3. Reverse the procedure for spark plug installation. Torque to

specification.

Plug Condition Torque Specification New Spark Plug 9 ft-lbs (12 Nm)

Previously Installed Spark Plug 9 ft-lbs (12 Nm)

119

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.

120

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 ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the

footrests. 2. Check the air box. If water is present, dry the air box and replace the

filter with a new filter. 3. Remove the spark plug. 4. Turn the engine over several times using the electric start. 5. Dry the spark plug. Reinstall the plug or install a new plug. 6. Attempt to start the engine. If necessary, repeat the drying

procedure. 7. Take the ATV 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 124 for drying out the PVT.

121

MAINTENANCE Spark Arrester

Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrester while the system is hot. Allow components to cool sufficiently before proceeding.

Use the following procedure to periodically purge accumulated carbon from the exhaust pipe/muffler. 1. Remove the arrester clean-

out plug from the bottom of the muffler.

2. Place the transmission in PARK.

3. Start the engine. 4. Quickly squeeze and release

the throttle lever several times to purge carbon from the system.

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

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

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

8. Repeat steps 4 to 6 until no more particles are expelled. 9. Stop the engine. Allow the arrester to cool. 10. Reinstall the arrester plug and remove the exhaust outlet cover or

plug.

WARNING

Exhaust Outlet

Clean-Out Plug

122

MAINTENANCE PVT System

Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components. The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe: Always follow all recommended maintenance procedures. Always look for

and remove debris inside and around the clutch and vent system when replacing the belt.

See your dealer as outlined in the owner's manual. This PVT system is intended for use on POLARIS products only. Do not

install it in any other product. Always make sure the PVT housing is securely in place during operation.

WARNING

123

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. On POLARIS ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed. For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1200 - 1400 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.).

124

MAINTENANCE PVT System When to Use Low Range and High Range

PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Position the vehicle on a level surface. 2. Remove the drain plug. Allow the water to drain completely.

Reinstall the drain plug. 3. Start the engine. Place the transmission in PARK. 4. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.

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

6. Test for belt slippage. If the belt slips, repeat the process. 7. Take the vehicle to your dealer for service as soon as possible.

Condition Range to Use Operating at speeds less than 7 MPH (11 km/h) Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High

125

MAINTENANCE Battery

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

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water. Internal: Drink large quantities of water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician immediately. Eyes: Flush with water for 15 minutes and get prompt medical attention. Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away. Ventilate when charging or using in an enclosed space. Always shield eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN. Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly. Be careful not to allow cleaning solution or tap water into a conventional battery.

WARNING

WARNING

126

MAINTENANCE Battery Battery Removal 1. Disconnect the battery hold-down strap. 2. Remove the battery cover (if equipped). 3. On conventional batteries, remove the battery vent tube. 4. Disconnect the black (negative) battery cable first. 5. Disconnect the red (positive) battery cable last. 6. Lift the battery out of the ATV. Be careful not to tip a conventional

battery sideways, which could spill electrolyte. NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the vehicle.

127

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 129 before installing the battery. An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, please see your POLARIS dealer. Ask your dealer to provide any installation procedures that may differ for an extreme use battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed

batteries do not have a vent tube). The vent tube must be free of obstructions and securely installed. Route the tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube and cause an explosion, resulting in serious injury or death. Always ensure that the vent tube is free of obstructions and is securely installed as recommended. 4. On conventional batteries, coat the terminals with dielectric grease

or petroleum jelly. 5. Connect and tighten the red (positive) cable first. 6. Connect and tighten the black (negative) cable last. 7. Install the battery cover (if equipped). 8. Secure the battery hold-down strap. 9. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

128

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 152 for the part numbers of POLARIS products.

Battery Fluid (Conventional Battery) A poorly maintained battery will deteriorate rapidly. Check the battery fluid level often. Maintain the fluid level between the upper and lower level marks. Add only distilled water. Tap water contains minerals that are harmful to a battery.

Lower Mark

Upper Mark

129

MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from

leaking or spilled electrolyte during charging. See page 126. 2. Charge the battery with a charging output no larger than 1/10 of the

batterys amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 127. Make sure the positive terminal is toward the front of the vehicle.

Battery Charging (Sealed Battery) The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with electrolyte and has been sealed and fully charged at the factory. Never pry the sealing strip off or add any other fluid to this battery. The single most important thing about maintaining a sealed battery is to keep it fully charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully. 1. 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.

130

MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging.

State of Charge Voltage Action

Charge Time (Using constant current

charger @ standard amps specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no charge given,

check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours 25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

verify state of charge 0%-25% 11.5 volts or less Needs charge with

desulfating charger At least 20 hours

131

MAINTENANCE Camber and Caster The camber and caster are non-adjustable.

Rear Spring The rear shock absorber spring is adjusted by rotating the cam either clockwise or counter-clockwise to increase or decrease spring tension.

Front Spring (570 SP only) The front shock absorber spring is adjusted by rotating the cam either clockwise or counter-clockwise to increase or decrease spring tension.

High Tension

Low Tension

Cam

132

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

1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired

height. 4. 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.

5. 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

133

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.

134

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 Brakes Cab and body panels Electrical components Switches and controls Labels 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.

135

MAINTENANCE Cleaning and Storage Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a like new appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces. 2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion. 3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish. 4. Routinely and liberally apply a weather resistant wax to each

polished chrome wheel. Choose a product suitable for chrome finishes. Read and follow the product labels and instructions.

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

136

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 133.

Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel

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

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

Oil and Filter Change the oil and filter. See page 95.

Air Filter/Air Box 1. Inspect and clean (or replace) the pre-cleaner and air filter. See page

109. 2. Clean the air box. 3. Drain the sediment tube. 4. Clean or replace the breather valve. See page 110.

137

MAINTENANCE Cleaning and Storage Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 88. Demand drive unit (front gearcase) Rear gearcase (if equipped) Transmission Brake fluid (change every two years and any time the fluid looks dark

or contaminated) Coolant (test strength/fill)

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 the spark plug cap and

reinstall the caps onto the plugs. 4. Turn the engine over several times using electric start. Oil will be

forced in and around the piston rings and ring lands, coating the cylinder with a protective film of fresh oil.

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

138

MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 88.

Battery Storage See pages 128-129 for storage and charging procedures.

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

Accessories Auxiliary power outlets provide 12-volt power for operating accessories. Accessory outlets are available for all models. POLARIS also has a wide range of additional accessories available for your ATV. Always install accessories that are approved for ATV use. Please see your POLARIS dealer.

139

MAINTENANCE Transporting the ATV Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in

PARK. 3. Lock the parking brake. 4. Secure the fuel cap, oil cap

and seat. 5. Always tie the frame of the

ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets, racks or handlebars.

6. Remove the key to prevent loss during transporting.

Rear

Front

140

TROUBLESHOOTING Drive Belt Wear/Burn

Possible Cause Solution Driving onto a pickup or tall trailer in high range

Use low range during loading.

Starting out going up a steep incline

Use low range or turn around using the K-turn (see page 66).

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

Drive at a higher speed or use low range more frequently. See page 124.

Insufficient warm-up at low ambient temperatures

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

Slow/easy clutch engagement

Use the throttle quickly and effectively.

Towing/pushing at low RPM/low ground speed

Use low range only.

Utility use/plowing Use low range only. Stuck in mud or snow Shift the transmission to low range and carefully use fast,

aggressive throttle application to engage clutch. WARNING! Excessive throttle may cause loss of control and vehicle rollover.

Climbing over large objects from a stopped position

Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch. WARNING! Excessive throttle may cause loss of control and vehicle rollover.

Belt slippage from water or snow ingestion into the PVT system

Dry out the PVT. See page 124. Inspect clutch seals for damage if repeated leaking occurs.

Clutch malfunction See your POLARIS dealer. Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer. Slippage from failure to warm up belt

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

Wrong or missing belt Install the recommended belt. Improper break-in Always break in a new belt and/or clutch. See page 54.

141

TROUBLESHOOTING Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Possible Cause Solution Tripped circuit breaker or blown fuse Reset the breaker/Replace fuse Low battery voltage Recharge the battery to 12.8 VDC Loose battery connections Check all connections and tighten Loose solenoid connections Check all connections and tighten

Possible Cause Solution Out of fuel Refuel, cycle key to ON position three

times for 5 seconds each, then start Clogged fuel filter Replace the filter Water is present in fuel Drain the fuel system and refuel Old or non-recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs, verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12.8 VDC Mechanical failure See your dealer

Possible Cause Solution Weak spark from spark plug Inspect, clean and/or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non-recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition timing See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel

142

TROUBLESHOOTING Engine Pings or Knocks

Engine Runs Irregularly, Stalls or Misfires

Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel Incorrect ignition timing See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs

Possible Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer

Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommended fuel Clogged fuel filter Replace filter Incorrect fuel Replace with recommended fuel

Possible Rich Fuel Cause Solution Fuel is very high octane Replace with lower octane fuel Stopping/starting without adequate warm-up

Allow engine to warm up before operating and/or stopping

Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace

143

TROUBLESHOOTING Engine Stops or Loses Power

Engine Overheating

Possible Cause Solution Out of fuel Refuel, cycle key to ON position three

times for 5 seconds each, then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect, clean and/or replace spark plugs Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12.8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core, clean

engine exterior, see your dealer

Possible Cause Solution Debris lodged in screen Remove and clean the screen. Pull on the

top portion of the screen, then remove the lower portion.

Plugged Radiator 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.

144

SPECIFICATIONS

* Based on EU Directive 76/432/EC

SPORTSMAN 450 HO/450 HO 2X4/570/570 EPS/570 SP Maximum Weight Capacity 220 kg (operator, cargo, accessories) Dry Weight 314 kg (450 HO)

300 kg (450 HO 2X4) 318.4 kg (570) 323.4 kg (570 EPS) 331 kg (570 SP)

Fuel Capacity 17 L Engine Oil Capacity 1.9 L Transmission Oil Capacity 948 ml Demand Drive Fluid Capacity 265 ml Coolant Capacity 2.5 l Front Rack/Box Capacity 41 kg Rear Rack/Box Capacity 82 kg Receiver Hitch Tongue Capacity 55 kg* (450 HO/2X4/570/570 EPS)

68 kg* (570 SP) *Rear rack capacity and tongue weight not to exceed 82 kg

Hitch Towing Rating 557 kg (450 HO/2X4/570/570 EPS) 680 kg (570 SP)

Unbraked Trailer Towing Capacity*

810 kg

Overall Length/Width/Height 211 cm / 122 cm / 122 cm Wheelbase 128.3 cm Ground Clearance 28 cm (450 HO/2X4/570/570 EPS)

30.5 cm (570 SP) Minimum Turning Radius 165 cm unloaded Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73.6mm Alternator Output 660 W @ 7000 RPM Compression Ratio 10:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug / Gap MR7F/ 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 21 cm travel (450 HO/2X4/570/

570 EPS) Double A-Arm with 21 cm travel (570 SP)

Rear Suspension Progressive rate with 24 cm travel Shift Type H/L/N/R/P

145

SPECIFICATIONS

Clutching Chart

*EBS models require no helix/spring adjustment

SPORTSMAN 450 HO/450 HO 2X4/570/570 EPS/570 SP Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.82:1 (450 HO/570/570 EPS)

3.25:1 (570 SP) Tires/Pressure, Front 24x8-12 / 35 kPa (450 HO/2X4)

25x8-12 / 35 kPa (570/570 EPS) 26x8-14 / 35 kPa (570 SP)

Tires/Pressure, Rear 24x10-12 / 35 kPa (450 HO/2X4) 25x10-12 / 35 kPa (570) 25x11-12 / 35 kPa (570 EPS) 26x10-14 / 35 kPa (570 SP)

Brakes, Front/Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc Brake, Parking Hydraulic lock, all wheel Headlight (570/EPS/SP) 1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt) Headlight (450 HO/2X4) 2 Dual Beam on Bumper (50 watt) Taillights 8.26 watts Brake Light 26.9 watts Instrument Cluster LCD

Altitude Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix*

Meters (Feet)

0-1800 (0-6000)

25-52G PN 5632409

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

1800-3700 (6000-12000)

25-48 PN 5633217

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

146

SPECIFICATIONS

* Based on EU Directive 76/432/EC

SPORTSMAN 450 HO/570 EPS Zugmachine Maximum Weight Capacity 220 kg (operator, cargo, accessories) Dry Weight 314 kg (450 HO)

323.4 kg (570 EPS) Fuel Capacity 17 L Engine Oil Capacity 1.9 L Transmission Oil Capacity 948 ml Demand Drive Fluid Capacity 265 ml Coolant Capacity 2.5 L Front Rack/Box Capacity 41 kg Rear Rack/Box Capacity 82 kg Receiver Hitch Tongue Capacity 55 kg (Rear rack capacity and tongue weight not to

exceed 82 kg) Hitch Towing Rating 557 kg Unbraked Trailer Towing Capacity*

810 kg

Overall Length/Width/Height 211 cm / 122 cm / 122 cm Wheelbase 128.3 cm Ground Clearance 28 cm Minimum Turning Radius 165 cm unloaded Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73.6mm Alternator Output 660 W @ 7000 RPM Compression Ratio 10:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug / Gap MR7F/ 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 21 cm travel Rear Suspension Progressive rate with 24 cm travel Shift Type H/L/N/R/P

147

SPECIFICATIONS

Clutching Chart

*EBS models require no helix/spring adjustment

SPORTSMAN 450 HO/570 EPS Zugmachine Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.82:1 Tires/Pressure, Front 25x8-12 / 35 kPa Tires/Pressure, Rear 25x11-12 / 35 kPa Brakes, Front/Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc Brake, Parking Hydraulic lock, all wheel Headlight (450 HO) 2 Dual Beam on Bumper (50 watt) Headlight (570 EPS) 1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt) Taillights 8.26 watts Brake Light 26.9 watts Instrument Cluster LCD

Altitude Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix*

Meters (Feet)

0-1800 (0-6000)

25-52G PN 5632409

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

1800-3700 (6000-12000)

25-48 PN 5633217

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

148

SPECIFICATIONS

* Based on EU Directive 76/432/EC

SPORTSMAN Touring 570/570 EPS Maximum Weight Capacity 220 kg (includes operator, passenger, cargo, accessories) Dry Weight 330.2 kg (570)

335.2 kg (570 EPS) Fuel Capacity 17 L Engine Oil Capacity 1.9 L Transmission Oil Capacity 948 ml Demand Drive Fluid Capacity 265 ml Coolant Capacity 2.5 L Front Rack/Box Capacity 41 kg Rear Rack/Box Capacity 82 kg Receiver Hitch Tongue Capacity 55 kg (Rear rack capacity and tongue weight not to exceed

82 kg) Hitch Towing Rating 557 kg Unbraked Trailer Towing Capacity*

810 kg

Overall Length/Width/Height 218.4 cm / 122 cm / 122 cm Wheelbase 142.2 cm Ground Clearance 28 cm Minimum Turning Radius 208.3 cm unloaded Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73.6mm Alternator Output 660 W @ 7000 RPM Compression Ratio 10:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug / Gap MR7F/ 0.7-0.8 mm Lubrication System Wet Sump

149

SPECIFICATIONS

Clutching Chart

*EBS models require no helix/spring adjustment

SPORTSMAN Touring 570/570 EPS Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 21 cm travel Rear Suspension Progressive rate with 24 cm travel Shift Type H/L/N/R/P Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.82:1 Tires/Pressure/Speed & Load Rating, Front

25x8-12 / 35 kPa / 43F

Tires/Pressure/Speed & Load Rating, Rear

25x10-12 / 35 kPa / 53F (570) 25x11-12 / 35 kPa / 53F (570 EPS)

Brakes, Front/Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt) Taillights 8.26 watts Brake Light 26.9 watts Instrument Cluster LCD

Altitude Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix*

Meters (Feet)

0-1800 (0-6000)

25-52G PN 5632409

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

1800-3700 (6000-12000)

25-48 PN 5633217

Black PN 7043594

Red PN 3234451

EBS PN 3235639

150

SPECIFICATIONS

* Based on EU Directive 76/432/EC

SPORTSMAN UTE 570 Maximum Weight Capacity 320 kg (operator, cargo, accessories) Dry Weight 354 kg Fuel Capacity 17 L Engine Oil Capacity 1.9 L Transmission Oil Capacity 948 ml Demand Drive Fluid Capacity 265 ml Coolant Capacity 2.5 L Front Rack/Box Capacity 40.8 kg Rear Rack/Cargo Box Capacity 181.4 kg Receiver Hitch Tongue Capacity 54 kg (Rear box capacity and tongue weight not to exceed

81.4 kg) Hitch Towing Rating 555.7 kg Unbraked Trailer Towing Capacity*

810 kg

Overall Length/Width/Height 226 cm / 122 cm / 122 cm Wheelbase 142.2 cm Ground Clearance 28 cm Minimum Turning Radius 208.3 cm unloaded Engine Dual overhead cam, 4 valve 4 stroke single cylinder Displacement 567 cc Bore x Stroke 99mm x 73.6mm Alternator Output 560 W @ 7000 RPM Compression Ratio 10:1 Starting System Electric Fuel System Electronic Fuel Injection Ignition System ECU Spark Plug / Gap MR7F/ 0.7-0.8 mm Lubrication System Wet Sump Driving System Type Automatic PVT (POLARIS Variable Transmission) Front Suspension MacPherson strut with 21 cm travel Rear Suspension Progressive rate with 24 cm travel Shift Type H/L/N/R/P

151

SPECIFICATIONS

Clutching Chart

*EBS models require no helix/spring adjustment

SPORTSMAN UTE 570 Gear Reduction, Low 23.91:1 Gear Reduction, Reverse 21.74:1 Gear Reduction, Forward 9.75:1 Drive Ratio, Front 3.25:1 Tires/Pressure, Front 25x8-12 / 35 kPa Tires/Pressure, Rear 25x12.5-12 / 35 kPa Brakes, Front/Rear Single-Control Hydraulic Disc Brake, Auxiliary Foot-Activated Hydraulic Disc Brake, Parking Hydraulic lock, all wheel Headlight 1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (50 watt) Taillights 8.26 watts Brake Light 26.9 watts Instrument Cluster LCD

Altitude Shift Weight

Drive Clutch Spring

Driven Clutch Spring

Helix*

Meters (Feet)

0-1800 (0-6000)

25-52G PN 5632409

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

1800-3700 (6000-12000)

25-48 PN 5633217

Black PN 7043594

Red PN 3234451

EBS PN 3235639

Non-EBS PN 5132344

152

POLARIS PRODUCTS Part Number Description

Engine Lubricant 2870791 Fogging Oil (Aerosol) 2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (.95 L) 2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (3.8 L) 2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (.95 L) 2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (3.8 L)

Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid

(.95 L) 2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid

(3.8 L) 2877922 Demand Drive Plus Fluid (.95 L) 2877923 Demand Drive Plus Fluid (3.8 L) 2870465 Pump for 3.8 L Jug

Coolant 2880514 Antifreeze 50/50 Premix (.95 L) 2880513 Antifreeze 50/50 Premix (3.8 L)

Grease / Specialized Lubricants 2871312 Grease Gun Kit, Premium All Season 2871322 All Season Grease (89 ml cartridge) 2871423 All Season Grease (414 ml cartridge) 2871460 Premium Starter Grease 2871515 U-Joint Grease (89 ml cartridge) 2871551 U-Joint Grease (414 ml cartridge) 2871329 Dielectric Grease (Nyogel)

Additives / Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 2871956 Loctite 565 Thread Sealant 2859044 POLARIS Battery Tender Charger

153

WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a TWO YEAR LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

Registration At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.

Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed. This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

154

WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:

Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty. This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time. THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

Wheels and tires Finished and unfinished surfaces Suspension components Carburetor/Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components and fluids Steering components Circuit breakers/Fuses Batteries Electronic components Light bulbs/Sealed beam lamps Spark plugs Filters Sealants Lubricants Coolants Bushings Bearings

155

WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. In the Country where your product was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product was purchased: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair. If you move: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle. If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins.

156

WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.

157

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

158

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

159

MAINTENANCE LOG

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

160

INDEX 0-9

4WDC System . . . . . . . . . . . . . . . . . 39 4X4 Switch . . . . . . . . . . . . . . . . . . . 28

A Accessories . . . . . . . . . . . . . . . . . . 138 Age Restrictions. . . . . . . . . . . . . . . . . 8 Air Filter . . . . . . . . . . . . . . . . . . . . 109 All Wheel Drive System . . . . . . . 37-39 Auxiliary Foot Brake . . . . . . . . . . . 102 AWD Momentary Switch . . . . . . . . 37

B Battery

Charging (Conventional) . . . . . 129 Charging (Sealed) . . . . . . . . 129-130 Extreme Use . . . . . . . . . . . . . . . . 36 Fluid (Conventional). . . . . . . . . 128 Installation . . . . . . . . . . . . . . . . 127 Removal . . . . . . . . . . . . . . . . . . 126 Storage . . . . . . . . . . . . . . . . . . . 128

Belt Life . . . . . . . . . . . . . . . . . . . . . . 36 Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake Fluid, Auxiliary Foot Brake . 34 Brake Fluid, Main Brake System. . . 32 Brake Lever . . . . . . . . . . . . . . . . . . . 31 Brake, Foot . . . . . . . . . . . . . . . 34, 102 Brake, Hand Lever. . . . . . . . . . . . . 102 Brake, Parking . . . . . . . . . . . . . . . . . 33 Brakelight Lamp Replacement . . . 117 Brakes . . . . . . . . . . . . . . . . . . . . . . 102 Break-In Period . . . . . . . . . . . . . . 53-54 Breather Hose . . . . . . . . . . . . . . . . 110 Breather Valve . . . . . . . . . . . . . . . . 110

C Camber Adjustment . . . . . . . . . . . . 131 Cargo . . . . . . . . . . . . . . . . . . . . . . 70-73 Caster Adjustment . . . . . . . . . . . . . 131 Check Engine Indicator . . . . . . . . . . 47 Chrome Wheel Care . . . . . . . . . . . 135 Cleaning and Storage. . . . . . . . 133-138 Clothing . . . . . . . . . . . . . . . . . . . . . . . 9 Clutching Chart . . . 145, 147, 149, 151 Coolant Bottle . . . . . . . . . . . . . . . . 100 Coolant, Radiator. . . . . . . . . . . . . . 101 Cooling System . . . . . . . . . . . . 100-101 Corrosion Removal, Chrome. . . . . 135

D Declaration of Conformity. . . . . . . . . . 6 Demand Drive Fluid . . . . . . . . . . 98-99 Diagnostic Codes. . . . . . . . . . . . . 48-52 Disengaging 4WDC. . . . . . . . . . . . . . 39 Display Units, Standard/Metric . . . . . 44 Drive Belt Wear/Burn . . . . . . . . . . . 140 Drivetrain Break-In . . . . . . . . . . . . . . 53 Driving Downhill. . . . . . . . . . . . . . . . 65 Driving in Reverse. . . . . . . . . . . . . . . 69 Driving on a Sidehill . . . . . . . . . . . . . 64 Driving on Slippery Surfaces . . . . . . 62 Driving Over Obstacles . . . . . . . . . . . 74 Driving Procedures . . . . . . . . . . . . . . 58 Driving Through Water . . . . . . . . . . . 68 Driving Uphill . . . . . . . . . . . . . . . . . . 63 Driving with a Passenger. . . . . . . 59-60

E Electromagnetic Interference. . . . . . . 87 Electronic Power Steering . . . . . . . . . 35 Engaging 4WDC . . . . . . . . . . . . . . . . 39 Engine Break-In. . . . . . . . . . . . . . . . . 53 Engine Fogging . . . . . . . . . . . . . . . . 137 Engine Oil . . . . . . . . . . . . . . . . . . . . . 93 Equipment Modifications . . . . . . . . . . 8 Error Codes, Engine . . . . . . . . . . . . . 47 Exhaust Emission Control System . . 87 Extreme Use Battery . . . . . . . . . . . . . 36 Eye Protection . . . . . . . . . . . . . . . . . . . 9

F Fluid

Brake. . . . . . . . . . . . . . . . . . . . . . . 32 Coolant . . . . . . . . . . . . . . . . 100-101 Demand Drive. . . . . . . . . . . . . 98-99 Engine Oil . . . . . . . . . . . . . . . . 93-96 Transmission Oil. . . . . . . . . . . 97-98

Fluid Change Demand Drive. . . . . . . . . . . . . . . . 99 Engine Oil . . . . . . . . . . . . . . . . 95-96 Transmission. . . . . . . . . . . . . . . . . 98

Fluid Level Brake Fluid . . . . . . . . . . . . . . . . . . 34 Demand Drive. . . . . . . . . . . . . . . . 99 Engine Oil . . . . . . . . . . . . . . . . . . . 94 Transmission. . . . . . . . . . . . . . . . . 98

Foot Brake, Auxiliary . . . . . . . . . . . . 34

161

INDEX F

Footwell Removal. . . . . . . . . . 105-106 Footwell Support Removal . . . . . . . 106 Four-Wheel Descent Control System 39 Fuel Recommendations. . . . . . . . . . . 35 Fuel Safety . . . . . . . . . . . . . . . . . . . . 12 Fuel Tank Cap. . . . . . . . . . . . . . . . . . 35 Fuse Replacement . . . . . . . . . . . . . . 111

G Gasoline Handling . . . . . . . . . . . . . . 12 Gauge, Code Definitions. . . . . . . 48-52 Gauge, Digital/Analog . . . . . . . . 40-47 Gear Selector. . . . . . . . . . . . . . . . . . . 36 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9

H Hand Brake . . . . . . . . . . . . . . . . . . . 102 Handlebar Adjustment . . . . . . . . . . 132 Hauling Cargo. . . . . . . . . . . . . . . 70-73 Hazard Warning Switch . . . . . . . . . . 29 Headlight Housing Replacement

570 SP . . . . . . . . . . . . . . . . . . . . 116 570/570 EPS. . . . . . . . . . . . . . . . 115

Headlight Lamp Replacement . . . . 114 Headlight Switch. . . . . . . . . . . . . . . . 29 Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 9 High Beam Adjustment . . . . . 112-113 High Range Use . . . . . . . . . . . . . . . 124 Horn Switch . . . . . . . . . . . . . . . . . . . 29

I Immersion Maintenance . . . . . . . . . 120 Indicator Lamps . . . . . . . . . . . . . . . . 41 Instrument Cluster. . . . . . . . . . . . 40-52

K Key Switch . . . . . . . . . . . . . . . . . . . . 28 K-Turn . . . . . . . . . . . . . . . . . . . . 66-67

L Lights . . . . . . . . . . . . . . . . . . . 112-117

Headlight Housing (570/EPS) . . 115 Headlight Housing (570 SP) . . . 116 Headlight Lamp . . . . . . . . . . . . . 114 High Beam Adjustment . . . 112-113 Low Beam Adjustment . . . . . . . 113 Lower Headlamp Replacement . 117 Taillight/Brakelight . . . . . . . . . . 117

L Low Beam Adjustment . . . . . . . . . . 113 Low Range Use. . . . . . . . . . . . . . . . 124 Lower Headlamp Replacement. . . . 117 Lubrication Guide . . . . . . . . . . . . . . . 92

M Maintenance Chart . . . . . . . . . . . 88-91 Master Cylinder . . . . . . . . . . . . . . . . 32 Metric Display . . . . . . . . . . . . . . . . . 44 Mirrors . . . . . . . . . . . . . . . . . . . . . . . 28 Mode Switch . . . . . . . . . . . . . . . . . . . 28 Modifications . . . . . . . . . . . . . . . . . . . 8

N Noise Emission Control System . . . . 87

O Oil

Engine . . . . . . . . . . . . . . . . . . 93-96 Transmission . . . . . . . . . . . . . 97-98

Oil and Filter Change . . . . . . . . . 95-96 Oil Change, Transmission . . . . . . . . 98 Oil Level

Engine . . . . . . . . . . . . . . . . . . . . . 94 Transmission . . . . . . . . . . . . . . . . 98

Oil Recommendations . . . . . . . . . . . 93 Override Switch . . . . . . . . . . . . . . . . 28

P Parking Brake . . . . . . . . . . . . . . . . . . 33 Parking on an Incline . . . . . . . . . . . . 74 Periodic Maintenance Chart . . . . 88-91 Polaris Product List. . . . . . . . . . . . . 152 Polishing the Vehicle . . . . . . . . . . . 134 Power Steering . . . . . . . . . . . . . . . . . 35 Power Steering Unit (Cleaning) . . . 104 Pre-Ride Checklist . . . . . . . . . . . . . . 56 Protective Apparel . . . . . . . . . . . . . . 11 PVT Break-In . . . . . . . . . . . . . . . . . . 54 PVT Drying . . . . . . . . . . . . . . . . . . 124 PVT System . . . . . . . . . . . . . . 122-124

R Registration, Warranty . . . . . . . . . . 153 Reverse Operation . . . . . . . . . . . . . . 69 Reverse Override Switch . . . . . . . . . 28 Rider Information Center . . . . . . 42-47 Riding Gear. . . . . . . . . . . . . . . . . . . . . 9

162

INDEX S

Safe Operation Practices . . . . . . . 54-55 Safety Labels . . . . . . . . . . . . . . . . 20-27 Safety Training . . . . . . . . . . . . . . . . . 8 Safety Warnings. . . . . . . . . . . . . . 10-19 Safety, Winch Maintenance. . . . . . . 86 Seat Backrest Adjustment, Passenger 35 Severe Use . . . . . . . . . . . . . . . . . . . . 88 Shock Loading the Winch . . . . . . 84-85 Side Panel Removal. . . . . . . . . . . . 105 Sidehilling . . . . . . . . . . . . . . . . . . . . 64 Signal Words . . . . . . . . . . . . . . . . . . . 5 Spark Arrester . . . . . . . . . . . . . . . . 121 Spark Arrester Requirements. . . . . . 87 Spark Plug Inspection . . . . . . . 118-119 Spark Plug Recommendations. . . . 118 Spark Plug Torque Specification . . 118 Spark Plugs . . . . . . . . . . . . . . . 118-119 Specifications. . . . . . . . . . . . . . 144-149 Speedometer . . . . . . . . . . . . . . . . . . 40 Spring Adjustment

Front Shock (570 SP only) . . . . 131 Rear Shock . . . . . . . . . . . . . . . . 131

Starting the Engine . . . . . . . . . . . . . 57 Steering Assembly . . . . . . . . . . . . . 104 Steering Lock. . . . . . . . . . . . . . . . . . 30 Stop Switch . . . . . . . . . . . . . . . . . . . 29 Storage . . . . . . . . . . . . . . . . . . . 133-138 Storage Tips . . . . . . . . . . . . . . . 136-138 Switches

AWD Momentary Switch . . . . . . 37 Engine Stop Switch. . . . . . . . . . . 29 Hazard Warning . . . . . . . . . . . . . 29 Headlight Switch. . . . . . . . . . . . . 29 Horn . . . . . . . . . . . . . . . . . . . . . . 29 Main Key Switch . . . . . . . . . . . . 28 Mode/Reverse Override Switch . 28 Turn Signal . . . . . . . . . . . . . . . . . 29

T Taillight Lamp Replacement . . . . . . 117 Throttle Lever . . . . . . . . . . . . . . . . . . 30 Tires . . . . . . . . . . . . . . . . . . . . 107-108

Tread Depth . . . . . . . . . . . . . . . . 107 Wheel Installation . . . . . . . . . . . . 108 Wheel Nut Torque . . . . . . . . . . . 108 Wheel Removal . . . . . . . . . . . . . 107

Toe Alignment. . . . . . . . . . . . . . . . . 103 Towing Loads . . . . . . . . . . . . . . . . . . 72 Training . . . . . . . . . . . . . . . . . . . . . . . . 8 Transmission . . . . . . . . . . . . . . . . . . . 36 Transmission Oil . . . . . . . . . . . . . . . . 97 Transporting the ATV . . . . . . . . . . . 139 Turn Signal Switch . . . . . . . . . . . . . . 29 Turning Around on a Hill . . . . . . 66-67 Turning the Vehicle . . . . . . . . . . . . . . 61

V Vehicle Identification Numbers. . . . . . 7 Vehicle Immersion . . . . . . . . . . . . . 120 VIN . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

W Warning Symbols . . . . . . . . . . . . . . . . 5 Washing the Vehicle . . . . . . . . 133-134 Wheel Hub Tightening . . . . . . . . . . 107 Wheel Installation . . . . . . . . . . . . . . 108 Wheel Nut Torque Specifications . . 108 Wheel Removal . . . . . . . . . . . . . . . . 107 Winch Cable Care . . . . . . . . . . . . . . . 83 Winch Maintenance/Service Safety. . 86 Winch Operation . . . . . . . . . . . . . 78-82 Winch Safety Precautions . . . . . . 75-77 Winch Shock Loading . . . . . . . . . 84-85

For your nearest Polaris dealer, visit www.polaris.com

Polaris Sales Europe Sarl Route de lEtraz Business Center A5 1180 Rolle, Switzerland

Part No. 9926545 Rev

Manualsnet FAQs

If you want to find out how the 570 Polaris works, you can view and download the Polaris Sportsman 450, 570, Touring Owner' s Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Polaris 570 as well as other Polaris manuals. All you need to do is to use our search bar and find the user manual that you are looking for.

The Owner's Manual should include all the details that are needed to use a Polaris 570. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

The best way to navigate the Polaris Sportsman 450, 570, Touring Owner' s Manual is by checking the Table of Contents at the top of the page where available. This allows you to navigate a manual by jumping to the section you are looking for.

This Polaris Sportsman 450, 570, Touring Owner' s Manual consists of sections like Table of Contents, to name a few. For easier navigation, use the Table of Contents in the upper left corner.

You can download Polaris Sportsman 450, 570, Touring Owner' s Manual free of charge simply by clicking the “download” button in the upper right corner of any manuals page. This feature allows you to download any manual in a couple of seconds and is generally in PDF format. You can also save a manual for later by adding it to your saved documents in the user profile.

To be able to print Polaris Sportsman 450, 570, Touring Owner' s Manual, simply download the document to your computer. Once downloaded, open the PDF file and print the Polaris Sportsman 450, 570, Touring Owner' s Manual as you would any other document. This can usually be achieved by clicking on “File” and then “Print” from the menu bar.