Contents

Polaris Sportsman 850 Trail Edition v2 Owner's Manual PDF

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Summary of Content for Polaris Sportsman 850 Trail Edition v2 Owner's Manual PDF

WARNING 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.

Owner's Manual For Maintenance and Safety

SPORTSMAN 850 TRAIL EDITION

SPORTSMAN XP 1000 TRAIL EDITION

SPORTSMAN XP 1000 HUNTER EDITION

WARNING Operating, servicing, and maintaining a passenger vehicle or off-road

vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm. To minimize

exposure, avoid breathing exhaust, do not idle the engine except as necessary, service your vehicle in a well-ventilated area and wear gloves

or wash your hands frequently when servicing your vehicle.

For more information go to www.P65Warnings.ca.gov/passenger-vehicle.

! WARNING Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR

code with your smartphone.

!

2020 Owners Manual

Sportsman 850 Trail Edition Sportsman XP 1000 Trail Edition

Sportsman XP 1000 Hunter Edition

POLARIS, ACE, OUTLAW, SPORTSMAN, and SCRAMBLER are trademarks of POLARIS Industries Inc.

Copyright 2019 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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

Printed in U.S.A. 9930757

Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and recreational products. We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine weve ever produced.

Snowmobiles SPORTSMAN All-terrain vehicles Low emission vehicles (LEVs) RANGER utility vehicles POLARIS PRO XD work vehicles SLINGSHOT three wheel

motorcycles

RZR sport vehicles GEM vehicles INDIAN motorcycles POLARIS POWER generators POLARIS DEFENSE combat

vehicles Timbersled Snow Bikes

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and can be performed by a factory certified Master Service Dealer (MSD) technician.

Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Your POLARIS dealership can perform all of your service needs during, and after, the warranty period.

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WELCOME

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WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7 Safety . . . . . . . . . . . . . . . . . . . . . . 11 Features and Controls . . . . . . . . . . . . . . 27 Operation . . . . . . . . . . . . . . . . . . . . 59 Winch Guide. . . . . . . . . . . . . . . . . . . 77 Emission Control Systems . . . . . . . . . . . . . 87 Maintenance . . . . . . . . . . . . . . . . . . 89 Specifications . . . . . . . . . . . . . . . . . . 127 POLARIS Products . . . . . . . . . . . . . . . . 135 Troubleshooting . . . . . . . . . . . . . . . . . 137 Warranty . . . . . . . . . . . . . . . . . . . . 141 Maintenance Log . . . . . . . . . . . . . . . . 149

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INTRODUCTION IMPORTANT WARNING ABOUT THIS MANUAL

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles,

such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if

you fail to take proper precautions.

Read this owners manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV.

Never operate an ATV without proper instruction. Take a certified ATV safety training course (www.atvsafety.org).

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

Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course (www.atvsafety.org).

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INTRODUCTION

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

DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in

death or serious injury.

WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not

avoided, COULD result in serious injury or death.

CAUTION SAFETY ALERT CAUTION indicates a hazardous situation which, if not

avoided, COULD result in minor to moderate injury.

CAUTION CAUTION indicates special precautions that must be taken to avoid vehicle

damage or property damage.

IMPORTANT IMPORTANT provides key reminders during disassembly, assembly, and

inspection of components.

NOTICE

NOTICE provides key information by clarifying instructions.

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

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

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INTRODUCTION

EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997.

The operating conditions of the machinery during testing:

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

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

Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature

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

The manufacturers label is located on the front right side of the vehicle behind the radiator.

Vehicle Model Number

Frame VIN q

Engine Serial Number w

Key Number

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INTRODUCTION

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SAFETY SAFETY TRAINING ATV safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course.

If you purchased a new POLARIS ATV in the United States, your dealer provided information about the authorized ATV RiderCoursesm that is available to you and your eligible family members. This training is included in the purchase price of your ATV. You were also provided with printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used POLARIS ATV in the United States, you can enroll in the ATV RiderCoursesm for a fee. Call ATV Enrollment Express at (800) 887- 2887 or visit www.atvsafety.org. If you purchased a POLARIS ATV outside the United States, please contact your dealer or local law enforcement agencies for information about safety training.

A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your vehicle manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United States, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call POLARIS at 1-800-342-3764.

SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long- sleeve shirt, long pants, over-the-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury.

q Helmet w Eye Protection e Long Sleeves r Gloves t Long Pants y Over-the-Ankle Boots

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SAFETY

HELMET Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Clasp the buckle and pull each strap tight to ensure the helmet is properly secured to the head.

Parents should verify that young operators have a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

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

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

GLOVES Wear gloves for comfort and for protection from sun, cold weather and other elements.

BOOTS Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

CLOTHING Wear long sleeves and long pants to protect arms and legs.

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SAFETY

SAFETY WARNINGS WARNING

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

provided with your vehicle. See the OPERATION section of the owners manual for proper operating procedures.

OPERATING WITHOUT INSTRUCTION Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. All operators should review the safety DVD provided with this vehicle and take a ROHVA training course (www.rohva.org).

AGE RESTRICTIONS This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid drivers license. The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel (if equipped) or handlebars.

USING ALCOHOL OR DRUGS

WARNING Never consume alcohol or drugs before or while

operating this vehicle. Operating this vehicle after consuming alcohol or drugs could adversely affect operator judgment,

reaction time, balance and perception.

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SAFETY

FAILURE TO INSPECT BEFORE OPERATING WARNING

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition.

Always follow the inspection and maintenance procedures and schedules described in this owners manual.

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

area. Never carry fuel or other flammable liquids on this vehicle. Failure to follow

this instruction could lead to serious burn injuries or death. Do not smoke or allow open flames or sparks in or near the area where

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

and water and change clothing.

EXPOSURE TO EXHAUST CAUTION

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.

Operate this vehicle only outdoors or in well-ventilated areas.

PROTECTIVE APPAREL Riding in this vehicle without wearing an approved helmet and protective eye wear increases the risk of a serious injuries in the event of an accident.

Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

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SAFETY

OPERATING WITH PASSENGERS Never carry a passenger on a 1up vehicle (Type I). Never carry more than one passenger on a 2up

vehicle (Type II). Do not carry a passenger on a 2up vehicle until

you have at least two hours of driving experience.

OPERATING ON PAVEMENT This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.

OPERATING ON PUBLIC ROADS Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

OPERATING AT EXCESSIVE SPEEDS Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience.

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SAFETY

PHYSICAL CONTROL OF THE VEHICLE Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.

TURNING IMPROPERLY CAUTION

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this

owners manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.

JUMPS AND STUNTS Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, donuts, jumps or other driving stunts. Avoid exhibition driving.

IMPROPER HILL CLIMBING Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See the New Operator Driving Procedures section for details.

DESCENDING HILLS IMPROPERLY Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owners manual. See the New Operator Driving Procedures section for details.

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SAFETY

CROSSING HILLSIDES Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See the New Operator Driving Procedures section for details.

STALLING WHILE CLIMBING A HILL Stalling, rolling backwards or improperly dismounting while climbing a hill could cause a rollover. Always maintain a steady speed when climbing a

hill. Always move the 4X4 switch to ADC (if equipped)

before ascending or descending a hill.

If all forward speed is lost:

Lean forward to keep body weight uphill. A passenger should also lean uphill. Apply the brakes. Lock the parking brake when fully stopped. Dismount on the uphill side of the vehicle, or on the left if the vehicle is

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

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

If the ATV begins rolling downhill:

Keep operator and passenger body weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the hand brake

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

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

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

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

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SAFETY

OPERATING ON STEEP HILLS Operating on excessively steep hills could cause an overturn.

Never operate on hills too steep for the ATV or for your abilities. Never operate a 1-up ATV on hills steeper than 25 degrees.

OPERATING ON SLIPPERY TERRAIN Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the vehicle on such terrain. Always use extra caution on rough, slippery or loose terrain.

OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.

Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.

Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels.

OPERATING IMPROPERLY IN REVERSE Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See the New Operator Driving Procedures section for details.

Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

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SAFETY

OPERATING OVER OBSTACLES Improperly operating over obstacles could cause loss of control or rollover.

Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See the New Operator Driving Procedures section for details.

SKIDDING OR SLIDING Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See the New Operator Driving Procedures section for details.

OPERATING A DAMAGED VEHICLE CAUTION

Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection

devices, brakes, throttle, and steering systems.

OPERATING THROUGH WATER Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle.

Always follow proper procedures for operating in water as described in this owners manual. See page 65.

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

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SAFETY

IMPROPER CARGO LOADING Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident.

Always follow the instructions in this owners manual for carrying cargo. Never exceed the stated load capacity for this vehicle. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater

distance for braking.

OPERATING ON FROZEN BODIES OF WATER Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

POOR VISIBILITY CAUTION

Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle is not equipped with highway-approved lights. Operate this vehicle off-road only.

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

burned out headlamps promptly.

PHYSICAL SKILLS Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control.

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SAFETY

HOT EXHAUST SYSTEMS WARNING

Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust system.

Use caution when traveling through tall grass, especially dry grass, and when traveling in muddy conditions. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush, other tall ground cover, and muddy conditions. Promptly remove any grass,

debris, or foreign matter clinging to the vehicle. Pay particular attention to the exhaust system area.

UNAUTHORIZED USE OF THE VEHICLE Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

The POLARIS limited warranty on your POLARIS vehicle will be terminated if any non-POLARIS approved equipment and/or modifications have been added to the vehicle that increase speed or power.

The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.

FOR MORE INFORMATION ABOUT SAFETY call POLARIS at 1-800-342-3764.

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SAFETY

SAFETY LABELS AND LOCATIONS Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

q Age Warning t General Warning

w Reverse Override Warning/AWD Caution

y No Passenger Warning

e Discretionary Warning u Tire Pressure/Load Warning

r Rack/Box Warning i Clutch Warning (Under Seat)

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SAFETY

AGE 16 WARNING The Age 16 warning r is located on the left-hand wheel well.

WARNING Operating this vehicle if you are under the age of 16 increases the chances of severe injury or death to operator. NEVER operate this vehicle if you are under age 16.

REVERSE OVERRIDE WARNING/AWD CAUTION WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

CAUTION Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

DISCRETIONARY WARNING WARNING Never operate this ATV on HILLS steeper than 25

degrees 25. To prevent overturn on hilly terrain, use throttle and brakes gradually, and shift weight uphill.

REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent loss of control, avoid sudden braking or sharp turns.

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SAFETY

RACK/BOX WARNING WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch.

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

GENERAL WARNING WARNING Improper use can result in SEVERE INJURY or DEATH

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR

NEVER USE ON PUBLIC ROADS

NEVER CARRY PASSENGERS

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate: without proper training or instruction at speeds too fast for your skills or the conditions on public roads - a collision can occur with another vehicle with a passenger - passengers affect balance and steering and increase risk

of losing control

ALWAYS: use proper riding techniques to avoid vehicle overturns on hills and rough

terrain and in turns avoid paved surfaces - pavement may seriously affect handling and control

LOCATE AND READ OWNERS MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

NO PASSENGER WARNING WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in SEVERE INJURY or DEATH.

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SAFETY

TIRE PRESSURE/LOAD WARNING (TRAIL MODELS) WARNING Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death. Cold tire pressure:

Front: 10.0 psi (69 kPa) Rear: 10.0 psi (69 kPa)

Maximum weight capacity: 575 lbs. (261 kg) Lug nut torque values: Reference Owners Manual

NEVER exceed 62 MPH (100 km/h) when rear cargo loads are above 215 lbs. (98 kg).

TIRE PRESSURE/LOAD WARNING (HUNTER MODELS) WARNING Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death. Cold tire pressure:

Front: 7.0 psi (48.3 kPa) Rear: 7.0 psi (48.3 kPa)

Maximum weight capacity: 575 lbs. (261 kg) Lug nut torque values: Reference Owners Manual

NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 50 lbs. (22 kg) and/or front cargo loads are above 25 lbs. (11 kg).

NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).

CLUTCH COVER WARNING WARNING

Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.

Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.

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SAFETY

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FEATURES AND CONTROLS SWITCHES

NOTE Image below is for reference only. Your model may differ slightly.

q Ignition Switch w Engine Stop Switch e Mode/Reverse Override Switch

r Headlight Switch t Drive Line Switch y Auxiliary Outlet

IGNITION SWITCH/LIGHT SWITCH Use the ignition switch to start the engine. The key can be removed from the switch when it is in the OFF position.

OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off.

RUN Turn the key the RUN position to activate electrical components. Electrical circuits are on. Electrical equipment can be used.

START Turn the key to the START position to engage the electric starter. See the Starting the Engine section for starting procedures.

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FEATURES AND CONTROLS

AWD MODE SWITCH (IF EQUIPPED) The AWD switch q controls the All Wheel Drive (AWD) system. Use this switch to engage AWD or 2X4. The vehicle automatically engages AWD when operating in reverse if the drive mode is set to AWD.

ENGINE STOP SWITCH Move the stop switch w either left or right to the OFF position to stop the engine quickly. Move the stop switch to the RUN position before attempting to start the engine. The engine will not start or run when the switch is off. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

MODE/REVERSE OVERRIDE SWITCH WARNING

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

before pressing the override button.

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override button e. The reverse override button also acts as a MODE button when held down for approximately one half second. The override button will not function as a MODE button if the transmission is in reverse.

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FEATURES AND CONTROLS

HEADLIGHT SWITCH Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam. The key must be in the ON position and the engine stop switch must be in the RUN position.

THROTTLE LEVER WARNING

Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or

improperly operating throttle. Immediately contact your POLARIS dealer or other qualified person for service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check

occasionally during operation. Modifications to the electronic throttle control could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the

throttle control system or replace it with any after market throttle mechanisms.

Engine speed and vehicle movement are controlled by pressing the throttle lever q. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released. This ATV is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle.

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FEATURES AND CONTROLS

BRAKE LEVER WARNING

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

brake lever. Always contact your dealer for service before operating the vehicle.

Squeeze the brake lever q toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your POLARIS dealer or other qualified service facility for proper diagnosis and repairs.

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FEATURES AND CONTROLS

MASTER CYLINDER/BRAKE FLUID WARNING

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

not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake

fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid in the master cylinder before each ride.

1. Position the ATV on a level surface.

2. Position the handlebars so the master cylinder q is level.

3. View the brake fluid level through the indicator window w on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

4. If the fluid level is low, remove the cover screws and add fluid to the fill line. Do not overfill. Use DOT 4 brake fluid only.

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

31

FEATURES AND CONTROLS

PARKING BRAKE LOCKING THE PARKING BRAKE

WARNING Operating the ATV while the parking brake is engaged could result in an

accident or fire. Always check to be sure the parking brake is disengaged before operating.

1. Place the transmission in PARK.

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

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

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

32

FEATURES AND CONTROLS

AUXILIARY FOOT BRAKE WARNING

Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide

sideways, causing loss of control and serious injury or death.

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake q. The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot. If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

BRAKE FLUID LEVEL Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the front storage box.

Maintain the fluid level between the maximum and minimum marks. Use DOT 4 brake fluid only.

33

FEATURES AND CONTROLS

AUTOMATIC TRANSMISSION GEAR SELECTOR

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

H: High Gear L: Low Gear N: Neutral R: Reverse P: Park

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

NOTE Shifting gears with the engine speed above idle or while the vehicle is moving

could cause transmission damage.

Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.

TIP To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow

speed.

34

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 the Instrument Cluster section for EPS Warning Indicator information.

FUEL CAP This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition.

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

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87 = (R + M/2) octane. Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel.

FRONT COMPARTMENT

q Coolant Bottle Cap e Electrical/Fuse/Relay

w Radiator Cap r Battery

35

FEATURES AND CONTROLS

FRONT RACK If your model is equipped with front compartment storage, unlock both latches on each side and remove the cover to gain access.

ELECTRONIC POWER STEERING (EPS) Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See the Instrument Cluster section for EPS Warning Indicator information.

EXTREME USE BATTERY An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your POLARIS dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.

BATTERY CHARGE PORT Your vehicle is equipped with a battery charge port q. The battery charge port allows you to quickly and easily connect a battery charger to your vehicles battery. For more information see page 115

36

FEATURES AND CONTROLS

ALL WHEEL DRIVE SYSTEM The All Wheel Drive system is controlled by the AWD switch.

AWD Models ADC Models X2

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

4X4 MODE When the switch is on 4X4, the ATV is four-wheel drive, and the 4X4 indicator icon in the instrument cluster display will be visible.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle may remain in 4X4. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position.

2X4 MODE When the switch is on 2X4, the ATV is in two-wheel drive at all times.

ENGAGING 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3000. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

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

37

FEATURES AND CONTROLS

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

while the rear wheels have traction or are at rest.

ACTIVE DESCENT CONTROL (ADC) SYSTEM The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

ENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically engage when all four of the following conditions occur: The 4X4 switch must be in the ADC 4X4 position Vehicle speed must be 15 MPH (25 km/h) or less The throttle must be closed (throttle lever released) The transmission must be in gear (high, low or reverse)

DISENGAGING ACTIVE DESCENT CONTROL The ADC system will automatically disengage if at least one of the following conditions occur: The 4X4 switch is moved out of the ADC 4X4 position Vehicle speed exceeds 15 MPH (25 km/h) The throttle is open (throttle is applied) The transmission is shifted to neutral or park

38

FEATURES AND CONTROLS

INSTRUMENT CLUSTER OVERVIEW

NOTICE

The use of a high pressure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.

q Gear Indicator

H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park = Gear Signal Error (or shifter between gears)

w Display Area 2 This area displays odometer, trip meter, trip meter 2, voltage, engine temperature, engine hour meter, programmable service hour interval, ground speed, or engine RPM.

e Display Area 1 This area displays engine RPM, ground speed, or coolant temperature.

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

t Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See page 51 for more information.

y Clock The clock displays time in a 12-hour or 24-hour format.

u AWD Indicator Segments of the indicator illuminate based on drive mode engaged.

39

FEATURES AND CONTROLS

INDICATOR LAMPS

q Check Engine This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist.

w EPS Warning (if equipped)

This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.

e Engine Hot This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating condition exists.

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

t Helmet/Seat Belt This lamp flashes for several seconds when the key is turned to the ON position. The lamp is a reminder to wear helmet and seat belt (if equipped) before operating.

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

u Chassis Fault If applicable.

i Performance Limited

On models equipped with a low speed limiter, indicator light will remain on when low speed limiter is active.

40

FEATURES AND CONTROLS

DIGITAL GAUGE The instrument cluster displays critical vehicle information to the user.

NOTE Some features are not applicable to all models. The use of a high pressure

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

1. Gear Display - This area displays gear shifter position: H: High Gear

L: Low Gear

N: Neutral

R: Reverse Gear

P: Park : Gear Signal Error (or shifter between gears)

2. Display Area 1 - This area displays engine RPM, ground speed, or coolant temperature.

3. Display Area 2 -This area displays odometer, trip meter, trip meter 2, voltage, engine temperature, engine hour meter, programmable service hour interval, ground speed, or engine RPM.

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

5. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer can provide scheduled maintenance. See the Periodic Maintenance Chart section for more information.

6. Clock - The clock displays time in a 12-hour or 24-hour format.

7. AWD Indicator- Segments of the indicator illuminate based on drive mode engaged.

41

FEATURES AND CONTROLS

DISPLAY AREA 1

Pressing the MODE button will change the information displayed in Area 1 q.

Speed Engine Temperature

RPM Ambient Temperature (Optional)

42

FEATURES AND CONTROLS

DISPLAY AREA 2

Toggle the Up/Down buttons to change the information displayed in Area 2 w.

Odometer Engine Temperature

Trip 1 Ambient Temperature (Optional)

43

FEATURES AND CONTROLS

Trip 2 RPM

Voltage Speed

Engine Hours Service Hours

44

FEATURES AND CONTROLS

OPTIONS MENU

Press and hold the MODE button to enter the Options Menu.

OPTIONS MENU NOTES

Diagnostic Codes Only displays if fault codes are present or stored

Units - Distance Select MPH or KPH

Units - Temp Select between F and C

Clock Select between 12H or 24H, and set time

Backlight Color Select between Blue or Red

Backlight Level Set backlight brightness level

Service Hours View/Set Service hours

Bluetooth Pairing Pair Bluetooth device

Exit Menu Exit

45

FEATURES AND CONTROLS

UNIT SELECTION DISTANCE

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Units-Distance from the Options Menu by pressing the MODE button.

Reference the image shown above:

q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (MPH or KPH)

e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

46

FEATURES AND CONTROLS

UNIT SELECTION TEMPERATURE

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Units - Temp from the Options Menu by pressing the MODE button.

Reference the image shown above:

q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (F or C)

e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

47

FEATURES AND CONTROLS

CLOCK

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Clock from the Options Menu by pressing the MODE button.

Reference the image shown above: q Press the MODE button. w Toggle the Up/Down Buttons to change the units (12H or 24H) e With the correct unit displayed, Press the mode button which will set the unit. r Toggle the Up/Down Buttons to change the units (Cycles Hours) t With the correct unit displayed, Press the mode button which will set the unit. y Toggle the Up/Down Buttons to change the units (Cycles 10s of Minutes) u With the correct unit displayed, Press the mode button which will set the unit. i Toggle the Up/Down Buttons to change the units (Cycles 1s of Minutes) o With the correct unit displayed. Press the mode button which will set the unit and return to the Options menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

48

FEATURES AND CONTROLS

BACK LIGHT COLOR

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Backlight Color from the Options Menu by pressing the MODE button.

Reference the image shown above:

q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (Blue or Red)

e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

49

FEATURES AND CONTROLS

BACK LIGHT LEVEL

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Backlight Level from the Options Menu by pressing the MODE button.

Reference the image shown above:

q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (Increase or De- crease Level)

e With the correct unit displayed, Press the mode button which will set the unit and return to the Options Menu.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

50

FEATURES AND CONTROLS

SERVICE HOURS

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Service Hours from the Options Menu by pressing the MODE button.

Reference the image shown above:

q Press the MODE button.

w Toggle the Up/Down Buttons to change the units (0, 5, 10 - 95, 100)

e With the correct unit displayed, press the MODE button, which will set the unit and return you to the Options Menu.

NOTICE

To reset service hours after they have counted down to "0.0", reselect the existing setpoint or select a new service hour value.

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

BLUETOOTH OPERATION (IF EQUIPPED) The Bluetooth functionality allows users to pair their phones with the vehicles digital gauge. This function allows users to receive call and text alerts while operating the vehicle.

PAIRING YOUR PHONE TO THE DIGITAL GAUGE Use the following procedure to pair your phone with the vehicles digital gauge.

51

FEATURES AND CONTROLS

NOTE Bluetooth functionality is compatible with both iOS and Android phones. For

iOS phones, you must go to the Settings option and enable notifications. Most Android phones will prompt the user automatically to enable notifications as

part of the pairing process.

1. Make sure Bluetooth is enabled on your phone.

2. Access the options menu on the vehicles digital gauge and select BT PAIR. The Bluetooth icon will begin to blink.

3. Find and select Polaris Gauge on your phones Bluetooth menu or prompt. Pairing should occur momentarily. Pairing mode will continue for up to 90 seconds or if you exit the BT PAIR menu.

After successfully pairing the phone, the vehicles digital gauge will automatically reconnect with the phone each time it is powered on and within range. No further action is required by the user at this point.

NOTE Once the digital gauge is powered off, Bluetooth connectivity will cease. Also,

when a new phone is paired with the digital gauge, all missed call and text information from the previous phone will be erased. Up to 16 different phone

pairings can be saved to the digital gauge. The digital gauge does not support systems below Android version 4.2 and iOS version 8.4.

SAFEGUARDS If a text message is received while the vehicle is moving faster than 2 KPH,

only the senders name is shown onscreen. If you are browsing any of the Bluetooth menus and the vehicle starts to move

faster than 2 KPH, the menu will automatically display VEHICLE MOVING. If you attempt to access Bluetooth menus while the vehicle is moving faster

than 2 KPH, the screen will display VEHICLE MOVING momentarily, and then it will redirect to the options menu.

52

FEATURES AND CONTROLS

DIAGNOSTIC CODE

NOTICE

Diagnostic Code Screen will show available MIL that has come on during that ignition cycle.

1. Press and hold the MODE button to enter the Options Menu.

NOTICE

OPTIONS will display on the screen for 3 seconds before showing first menu item.

2. Select Diagnostic Codes from the Options Menu by pressing the MODE button.

Toggle the Up/Down Buttons to cycle through Code(s).

NOTICE

This option will only be available if a fault code was set or is active during the current ignition key 'on' cycle. Turning off the ignition will clear any save fault

codes from the gauge.

Reference the image shown above:

q Area A will Display FMI (XX)

w Area B will Display SPN (XXXXXX)

e Clock Area will Display Count (XXX)

3. To exit the Options Menu the user can select Exit Menu function from Options Menu, can hold Mode Button and exit out of Options Menu, or not press any button for 10 seconds, which will exit out of the Options Menu.

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.

53

FEATURES AND CONTROLS

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

Throttle Position Sensor

Voltage Too High 51 3

Voltage Too Low 51 4

Engine Temperature Sensor

Voltage Too High 110 3

Voltage Too Low 110 4

Temperature Too High 110 16

Engine Overheat Shutdown 110 0

Intake Air Temperature Sensor

Voltage Too High 105 3

Voltage Too Low 105 4

Manifold Absolute Pressure Sensor

Voltage Too High 102 3

Voltage Too Low 102 4

Signal Out of Range 102 2

Crankshaft Position Sensor

Circuit Fault 636 8

Plausibility Fault 636 2

Vehicle Speed Signal Speed Too High 84 8

Plausibility Fault 84 2

Gear Sensor Signal Voltage Too Low 523 4

Voltage Too Low 523 3

Signal Fault 523 2

Injector 1 (MAG) (SDI Part Load)

Driver Circuit Open/ Grounded 651 5

Driver Circuit Short to B+ 651 3

Driver Circuit Grounded 651 4

54

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Injector 2 (PTO) (SDI Part Load)

Driver Circuit Open/ Grounded 652 5

Driver Circuit Short to B+ 652 3

Driver Circuit Grounded 652 4

Ignition Coil Primary Driver 1 (MAG)

Driver Circuit Short to B+ 1268 3

Ignition Coil Primary Driver 2 (PTO)

Driver Circuit Short to B+ 1269 3

Fuel Pump Driver Circuit

Driver Circuit Open/ Grounded 1347 5

Driver Circuit Short to B+ 1347 3

Driver Circuit Grounded 1347 4

Fan Relay Driver Circuit

Driver Circuit Open/ Grounded 1071 5

Driver Circuit Short to B+ 1071 3

Driver Circuit Grounded 1071 4

Idle Air Control Driver Circuit Open/ Grounded 634 5

Driver Circuit Short to B+ 634 3

Driver Circuit Grounded 634 4

Position Out of Range 634 7

Starter Enable Circuit Driver Circuit Open/ Grounded 1321 5

Driver Circuit Short to B+ 1321 3

Driver Circuit Grounded 1321 4

Chassis Relay Driver Circuit Open/ Grounded 520208 5

55

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Driver Circuit Short to B+ 520208 3

Driver Circuit Grounded 520208 4

All Wheel Drive Control

Driver Circuit Open/ Grounded 520207 5

Driver Circuit Short to B+ 520207 3

Driver Circuit Grounded 520207 4

System Power Voltage Too High 168 3

Voltage Too Low 168 4

Throttle Safety Signal Voltage Too High 520194 3

Voltage Too Low 520194 4

Signal Out of Range 520194 2

Throttle Stuck 520194 7

Active Descent Control System

Driver Circuit Open/ Grounded 520203 5

Driver Circuit Short to B+ 520203 3

Driver Circuit Grounded 520203 4

Idle Speed Speed Too High 520211 3

Speed Too Low 520211 4

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

EPS MODELS ONLY

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

84 0

56

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

EPS MODELS ONLY

Data Erratic, Intermittent Or Incorrect

84 2

Abnormal Rate Of Change 84 10

Received Network Data In Error 84 19

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

168 0

Voltage Above Normal, Or Shorted To High Source

168 3

Voltage Below Normal, Or Shorted To Low Source

168 4

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

190 0

Data Erratic, Intermittent Or Incorrect

190 2

Received Network Data In Error 190 19

ECU Memory Bad Intelligent Device Or Component 628 12

Out Of Calibration 628 13

Calibration Out Of Calibration 630 13

Steering Over Current Shut Down

Current Above Normal Or Grounded Circuit 520221 6

Steering Excessive Current Error

Current Above Normal Or Grounded Circuit 520222 6

Steering Torque Partial Failure

Condition Exists 520223 31

Steering Torque Full Failure

Condition Exists 520224 31

57

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

EPS MODELS ONLY

EPAS Inverter Temperature

Data Valid But Above Normal Operational Range - Most Severe Level

520225 0

Data Valid But Above Normal Operating Range - Moderately Severe Level

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

58

FEATURES AND CONTROLS

OPERATION IMPORTANT INFORMATION

WARNING Failure to operate the vehicle properly can result in a collision, loss of control,

accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owners

manual.

VEHICLE BREAK-IN PERIOD The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

NOTICE

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

or high speeds during the first three hours of use.

Use of any improper oils may cause serious engine damage. POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil is specifically formulated for your 4-cycle

engine.

59

OPERATION

ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with gasoline. See the Fuel Tank section for details. Always

exercise extreme caution whenever handling gasoline.

2. Check the oil level. See the Oil Check section for reference. Add the recommended oil as needed to maintain the oil level in the safe operating range.

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

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Pull only light loads.

7. Perform regular checks on fluid levels, controls and areas outlined on the daily pre-ride inspection checklist.

8. During the break-in period, change both the oil and the filter at 25 hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.

BRAKE SYSTEM BREAK-IN Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt.

60

OPERATION

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

ITEM REMARKS PAGE

Brake system/lever travel Ensure proper operation page 30 page 103

Brake fluid Ensure proper level page 33

Auxiliary brake Ensure proper operation page 33

Front suspension Inspect, lubricate if necessary -

Rear suspension Inspect, lubricate if necessary -

Steering Ensure free operation -

Tires Inspect condition and pressure page 104

Wheels/fasteners Inspect, ensure fastener tightness -

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels page 95

Coolant level Ensure proper level page 101

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation page 29

Indicator lights/switches Ensure operation page 40

Engine stop switch Ensure proper operation page 28

Air filter, pre-filter Inspect, clean page 106

Headlamp Check operation page 27

Brake light/taillight Check operation -

Riding gear Wear approved helmet, goggles, and protective clothing

page 11

61

OPERATION

ITEM REMARKS PAGE

Winch (if equipped) Inspect cable and switch page 77

Grass and leaves Remove grass, leaves, foreign matter, and other flammable material or debris, especially near the exhaust system.

-

SAFE OPERATION PRACTICES 1. Complete the recommended safety training before operating this vehicle.

Visit www.atvsafety.org for safety courses and riding tips. See page 11 for details.

2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

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

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

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

6. Operate this vehicle off-road only. Never operate the vehicle on pavement or on any public street, road or highway, including dirt and gravel roads.

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

8. Drive in a manner appropriate for your skills, your 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.

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

11. Never operate a damaged ATV. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage.

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

62

OPERATION

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.

TRAIL ETIQUETTE Always practice good etiquette when riding. Allow a safe distance between your vehicle and other vehicles operating in the same area. Communicate to oncoming operators by signaling the number of vehicles in your group. When stopping, move your vehicle to the edge of the trail as far as possible to allow others to pass safely.

KNOW YOUR RIDING AREA/TREAD LIGHTLY Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. Find out where the designated riding areas are by contacting your POLARIS dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow. Tread lightly. Operate with respect for the terrain, avoid littering, and always stay on the designated trails.

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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 brake is not

engaged.

4. Sit on the vehicle and move the engine stop switch to RUN.

TIP Do not press the throttle while starting the engine.

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

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

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

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

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OPERATION

NEW OPERATOR DRIVING PROCEDURES 1. Wear protective riding gear. See the Safe Riding Gear section.

2. Perform the pre-ride inspection.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

6. Sit upright with both feet on the footrests and both hands on the handlebars.

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

8. Shift the transmission into gear.

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

10. Release the parking brake.

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

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

TURNING THE VEHICLE Both rear wheels drive equally at all times. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.

1. Slow down.

2. Never turn quickly when carrying cargo.

3. Steer in the direction of the turn.

4. Keep both feet on the footrests.

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

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

WARNING Turning improperly can result in vehicle overturn. Never turn abruptly or at

sharp angles. Never turn at high speeds.

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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.

DRIVING UPHILL Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

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

2. Drive straight uphill.

3. Avoid steep hills. Maximum incline is 25

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

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

6. Keep both feet on the footrests.

7. Shift body weight uphill.

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

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OPERATION

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.

DRIVING DOWNHILL

When driving downhill, follow these precautions:

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

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

3. Avoid steep hills. Maximum incline is 25

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

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

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

7. Shift body weight uphill.

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

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OPERATION

DRIVING ON A SIDEHILL (SIDEHILLING) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

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

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

TURNING AROUND ON A HILL (K-TURN) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K- turn to turn around.

1. Stop and lock the parking brake while keeping body weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See the Switch Location section for details.

3. Leave the transmission in forward and shut off the engine.

4. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

5. Staying uphill of the vehicle, turn the handlebars full left.

6. While holding the brake lever, release the parking brake lock and slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

7. Lock the parking brake. Remount the vehicle from the uphill side, keeping body weight uphill. Start the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed with the brake lever, until the vehicle is on more level ground.

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OPERATION

DRIVING THROUGH WATER

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

1. Determine water depths and current before entering water.

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

3. Avoid operating through deep or fast-flowing water.

NOTICE

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the Periodic

Maintenance Chart. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings.

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, service is required before starting the engine. Your

POLARIS dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined in the Vehicle

Immersion section of this manual, and take the vehicle in for service at the first opportunity.

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.

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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.

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OPERATION

DRIVING IN REVERSE Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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

NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to

build in the exhaust, resulting in engine popping and/or engine damage.

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OPERATION

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

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

STOPPING THE ENGINE 1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

WARNING A rolling vehicle can cause serious injury. Always place the transmission in

PARK before stopping the engine.

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OPERATION

BRAKING 1. Release the throttle pedal completely.

CAUTION When the throttle pedal is released completely and engine speed slows to near

idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

PARKING THE VEHICLE 1. Stop the vehicle on a level surface. When parking inside a garage or other

structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Engage the parking brake (if equipped).

5. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle.

6. Remove the ignition key to prevent unauthorized use.

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OPERATION

HAULING CARGO WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can

result in serious injury or death. Always follow these precautions when hauling cargo:

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the

operator, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum

weight capacity. CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack

increases the possibility of vehicle overturn. CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads

high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the

vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point

designated for your vehicle. HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or

situations that may require backing downhill. USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The vehicle should never exceed 10 mph (16 kph) while towing a load on a

level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

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OPERATION

HAULING CARGO GUIDELINES 1. Never exceed the weight capacities specified for your ATV on warning labels

and in the specifications section of this manual

2. Cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.

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

4. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 10 MPH (16 km/h) when rear cargo loads are above 200 lbs. (91 kg) and/or front cargo loads are above 100 lbs. (45 kg).

5. Do not obstruct the headlight beam with cargo.

6. Slow down.

7. Use low forward gear when hauling or towing heavy cargo to extend belt life.

8. Always operate the vehicle with extreme caution whenever hauling or towing loads. Balance, handling and control may be affected.

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OPERATION

TOWING LOADS Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not

exceed the rear rack capacity. The total load (operator, accessories, cargo and weight on hitch) must not

exceed the maximum weight capacity of the vehicle.

NOTICE Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty.

Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or

equivalent) accessories designed for ATV use.

MAXIMUM TOWING CAPACITIES Do not exceed maximum towing capacities. Avoid towing on inclines.

850 MODELS XP 1000 MODELS

Maximum Towed Load (Level Ground) 1500 lbs. (680 kg) 1500 lbs. (680 kg)

Maximum Vertical Hitch Weight 150 lbs. (68 kg) 150 lbs. (68 kg)

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OPERATION

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

WARNING Improper winch use can result in SEVERE INJURY or DEATH. Always follow

all winch instructions and warnings in this manual.

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

WINCH SAFETY PRECAUTIONS 1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to jerk a load attached to the winch with a moving vehicle. See the Shock Loading section on page 85.

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.

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.

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WINCH GUIDE

12. If winching at an angle is unavoidable, follow these precautions:

a. Look at the winch drum occasionally. Never let the winch cable stack or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation.

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

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

20. Never use the winch to hoist or suspend a vertical load.

21. Always inspect your winch and winch cable before each use.

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WINCH GUIDE

22. Never winch the hook fully into the winch. This can cause damage to winch components.

23. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.

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

WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch.

TIP Consider practicing the operation and use of your winch before you actually

need to use it in the field.

WARNING

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

Each winching situation is unique.

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

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

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

2. Never operate a winch or a vehicle in need of repair or service.

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

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WINCH GUIDE

4. Always use the hook strap when handling the hook.

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

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

TIP A tow strap is NOT intended to stretch. A recovery strap is designed to

stretch.

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WINCH GUIDE

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 85.

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

WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace

POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer, or other

qualified dealer.

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

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

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

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

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the 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.

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WINCH GUIDE

8. Read and adhere to the following information for winch damping to ensure safe winch use.

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

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

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

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

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

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

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 85. 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.

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WINCH GUIDE

j. Detach the winch cable hook.

k. Rewind the winch cable evenly back onto the winch drum following the instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.

13. Extensive winching will run down the battery on the winching vehicle. Let the winching 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.

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WINCH GUIDE

WINCH CABLE CARE WARNING

Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.

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

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being straightened out, this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

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

A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown below). Promptly discontinue use of a winch cable in this condition. Also replace the winch cable if there are fused or melted fibers. Such an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

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WINCH GUIDE

SHOCK LOADING WARNING

Your winch cable is very strong but it is NOT designed for dynamic, or shock loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high

loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.

1. Never attempt to jerk a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

WARNING SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (jogging). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

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

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

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

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

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WINCH GUIDE

WINCH MAINTENANCE AND SERVICE SAFETY WARNING

Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this

manual.

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

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

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

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

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

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

WARNING Failure of a stretched rope under winching conditions will release all of the

stored energy. This will increase the chances of SEVERE INJURY or DEATH.

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WINCH GUIDE

EMISSION CONTROL SYSTEMS NOISE EMISSION CONTROL SYSTEM Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.

OPERATION ON PUBLIC LANDS IN THE U.S.A. Your vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1C. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

CRANKCASE EMISSION CONTROL SYSTEM This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.

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

The emissions label is located on the right front frame of the vehicle.

ELECTROMAGNETIC INTERFERENCE This spark ignition system complies with Canadian ICES-002.

This vehicle complies with the EMC requirements of UN ECE Regulation 10.

Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.

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EMISSION CONTROL SYSTEMS

88

MAINTENANCE PERIODIC MAINTENANCE Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicles emission controls. Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owners manual. Careful periodic maintenance will help keep your vehicle in safe, reliable condition. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer. Equivalent parts may be used for emissions-related service.

Record maintenance and service in the Maintenance Log beginning on page 149. Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, a qualified dealer can perform these operations. Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 miles per hour. Vehicles subjected to severe use must be inspected and serviced more frequently.

SEVERE USE DEFINITION Frequent immersion in mud, water or sand Frequent or prolonged operation in dusty environments Short trip cold weather operation Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle

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

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MAINTENANCE

MAINTENANCE CHART KEY SYMBOL DESCRIPTION

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

D Have an authorized Polaris dealer or other qualified person perform these services.

WARNING Improperly performing the procedures marked with a D could result in

component failure and lead to serious injury or death. Have an authorized POLARIS dealer or other qualified person perform these services.

Perform all services at whichever maintenance interval is reached first. Record maintenance and service in the Maintenance Log.

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HOUR-

S CALENDAR MILES (KM)

Steering

Pre-Ride Inspect and make adjustments as needed.

Front Suspension

Rear Suspension

Tires

Brake Fluid Level

Brake Lever Travel Brake System

Wheels / Fasteners

CV Boot

Frame Fasteners Engine Oil Level

Winch (if equipped)

XU Air Filter (Pre- Filter) - Daily - Inspect; clean often; replace as

needed

Air Box Sediment Tube - Daily - Drain deposits when visible

Coolant - Daily - Check level daily, change coolant every two years

Head Lights / Tail Lights - Daily - Check operation; apply dielectric

grease if replacing

Power Steering unit (If equipped)

- Daily Inspect daily, clean often

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MAINTENANCE

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HOUR-

S CALENDAR MILES (KM)

XU Air Filter (main element) - Weekly - Inspect; replace as needed

XU 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 - Turn key on to pressurize fuel pump, check lines/fittings for leaks and abrasion.

XU Engine Oil Change 25 H 1 M - Break-in oil and filter change

XU Demand Drive Fluid 25 H 1 M 250

(400) Break-in fluid level check

XU Rear Gearcase Oil 25 H 1 M 250 (400) Break-in fluid level check

XU Transmission Fluid 25 H 1 M 250 (400) Break-in fluid level check

Shift Linkage 50 H 3 M 500 (800) Inspect

D Steering 50 H 6 M 500 (800) Lubricate

XU Throttle Release Switch 50 H 6 M 500

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

Throttle Body Intake Duct 50 H 6 M 500

(800) Inspect ducts for proper sealing / air leaks

Drive Belt 50 H 6 M 500 (800)

Inspect ducts for proper sealing / air leaks

Cooling System 50 H 6 M 1000 (1600)

Inspect coolant strength seasonally; pressure test system yearly

XU Radiator 50 H 6 M 1000 (1600) Inspect; clean external surfaces

XU Cooling Hoses 50 H 6 M 1000 (1600) Inspect for leaks

XU Oil lines and fasteners 100 H 6 M 1000

(1600) Inspect for leaks and loose fittings

XU Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter

XU Demand drive fluid (normal use) 100 H 12 M 600

(1000) Change fluid

XU Rear gearcase oil 100 H 12 M 600 (1000) Change fluid

XU Transmission oil 100 H 12 M 600 (1000) Change fluid

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MAINTENANCE

ITEM

MAINTENANCE INTERVAL (WHICHEVER COMES FIRST)

REMARKS HOUR-

S CALENDAR MILES (KM)

D Fuel System 100 H 12 M 600 (1000)

Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/ rail and fuel pump

XU Engine Mounts 100 H 12 M 1000 (1600) Inspect

Exhaust Pipe / Silencer 100 H 12 M 1000

(1600) Inspect

XU Spark Plug 100 H 12 M 600 (1000) Inspect; replace as needed

XU Wiring 100 H 12 M 1000 (1600)

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

D Clutches (Drive/ Driven) 100 H 12 M 1000

(1600) Inspect; clean; replace worn parts

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

D Brake Fluid 200 H 24 M 2000 (3200) Change every two years

Spark Arrestor 300 H 36 M 3000 (4800) Clean out; or remove clean out plug

XU Coolant - 60 M - Replace coolant (50/50 Extended Life Coolant)

XU Valve Clearance 500 H - 5000 (8000) Inspect; adjust as needed

D Toe Adjustment - Inspect periodically; adjust as needed

Headlight Aim - Adjust as needed

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MAINTENANCE

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

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

ITEM RECOM- MENDED

LUBRICANT

CAPACITY AT FLUID CHANGE

FILL PLUG TORQUE

DRAIN PLUG

TORQUE

SEE PAGE

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

2 qt. (1.9 l)

12 ft-lbs (16 Nm)

page 94

Transmission Oil

AGL Gearcase

Lubricant & Transmission

Fluid

37 oz. (1100 ml)

10-14 ft-lbs (14-19 Nm)

10-14 ft-lbs (14-19 Nm)

page 98

Demand Drive Fluid

(Front Gearcase)

Demand Drive Fluid

9.3 oz. (275 ml)

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

11 ft-lbs (15 Nm)

page 99

Rear Gearcase Oil

ATV Angle Drive Fluid (or GL5 80- 90 weight gear lube)

7.1 oz. (210 ml)

10-14 ft-lbs (14-19 Nm)

10-14 ft-lbs (14-19 Nm)

page 100

Brake Fluid DOT 4 Brake Fluid

page 33

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.

A-Arms, Front and

Rear

POLARIS All- Season Grease

Grease fittings after extreme use or if suspension becomes squeaky.

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MAINTENANCE

ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil.

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

WARNING Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident and injury.

Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.

OIL RECOMMENDATIONS Always change the oil filter whenever changing oil.

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

See the Lubrication Guide section for fluid recommendations, capacities and plug torques.

NOTICE Mixing brands or using a non-recommended oil may cause serious engine

damage. Always use the recommended oil. Never substitute or mix oil brands.

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MAINTENANCE

OIL LEVEL

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

1. Position the vehicle on a level surface.

2. Access the oil dipstick and fill tube from the left side of the ATV q. Remove the dipstick. Wipe it dry with a clean cloth.

3. Reinstall and tighten the dipstick.

4. Remove the dipstick and check the oil level

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

6. Reinstall and tighten the dipstick.

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MAINTENANCE

OIL AND FILTER CHANGE See the fluid recommendation table for capacities and plug torques. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on . 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 crankcase.

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 specification.

9. Remove the oil filter cover plate by loosening the three screws holding into place.

10. 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.

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MAINTENANCE

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

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

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

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

15. Reinstall the dipstick.

16. Place the transmission in PARK.

17. Lock the parking brake.

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

19. Stop the engine.

20. Check for leaks.

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

22. Dispose of used filter and oil properly.

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MAINTENANCE

TRANSMISSION OIL Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. See the Fluid Recommendation table for capacities and plug torques. Maintain the oil level at the bottom of the fill plug hole w. The fill plug is located on the right side of the ATV behind the footwell. The drain plug q is located on the bottom rear side of the gearcase.

OIL CHECK 1. Remove the fill plug. Check the oil level.

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

3. Reinstall the fill plug. Torque to specification.

4. Reinstall the footwell.

OIL CHANGE 1. Place a drain pan under the gearcase. Remove the drain plug. Allow the oil

to drain completely.

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

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

4. Reinstall the fill plug. Torque to specification.

5. Check for leaks.

6. Reinstall the footwell.

7. Dispose of used oil properly.

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MAINTENANCE

FRONT GEARCASE (DEMAND DRIVE) FLUID Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart.

Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following: operation in ADC mode for prolonged periods constant ADC operation on hilly or mountainous terrain ADC is the primary mode of all-wheel-drive operation

TIP If the front gearcase is making excessive noise during ADC operation, change

the demand drive fluid. If the noise continues, please see your POLARIS dealer or other qualified service facility for service.

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

FLUID CHECK 1. Position the vehicle on a level

surface. Remove the fill plug q. Check the fluid level.

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

3. Reinstall the fill plug. Torque to specification.

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

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

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

4. Add the proper amount of the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

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

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MAINTENANCE

REAR GEARCASE OIL Always check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart. See page 135 for the part numbers of POLARIS products.

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

Maintain the fluid level at the bottom of the fill hole threads. Do not overfill.

OIL CHECK 1. Position the vehicle on a level

surface.

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

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

4. Reinstall the fill plug. Torque to specification.

OIL CHANGE 1. Position the vehicle on a level surface.

2. Place a drain pan under the drain holew.

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

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

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

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

8. Dispose of used oil properly.

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MAINTENANCE

POWER STEERING UNIT (IF EQUIPPED) If your model is equipped with power steering, frequently clean the areas around and on the power steering unit to allow proper cooling. Clean these areas e thoroughly.

STEERING ASSEMBLY The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your authorized dealer or other qualified service facility before operating the vehicle.

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

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

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

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See the Polaris Products section for the part numbers.

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MAINTENANCE

RECOVERY BOTTLE COOLANT The recovery bottle fluid level can be viewed from inside the front right wheel well. Access the recovery bottle cap under the front box.

1. View the fluid level in the bottle.

2. If the level is low, remove the bottle cap and add coolant as needed. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

3. Reinstall the cap.

4. Close and secure the front box and cover.

RADIATOR COOLANT To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

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

pressure cap.

1. Access the pressure cap under the front box. See the Front Compartment section for details.

2. Remove the pressure cap.

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

4. Reinstall the pressure cap. Use of a non-standard pressure cap will not allow the recovery system to function properly. Your POLARIS dealer can provide the correct replacement part.

5. Close and secure the front box and cover.

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MAINTENANCE

BRAKES HAND BRAKE The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self- adjusting.

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

WARNING An over-full master cylinder may cause brake drag or brake lock- up, which

could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

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

1. Always keep brake fluid at an adequate level. See the Master Cylinder/Brake Fluid section for details.

2. Check the brake system for fluid leaks.

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

4. Check the friction pads for wear, damage and looseness. Replace brake pads when they are worn to .030 (0.762 mm).

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

AUXILIARY FOOT BRAKE The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system.

SEAT REMOVAL 1. Locate the seat removal latch in the center of the seats rear.

2. Pull on the latch handle to disengage the seat from the vehicles frame.

3. Remove the seat.

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MAINTENANCE

TIRES WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an

accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always

use original equipment size and type when replacing tires.

Refer to the specifications section for recommended tire type, size and pressure.

TIRE TREAD DEPTH Always replace tires when tread depth is worn to 3 mm (1/8) or less.

FRONT WHEEL HUB TIGHTENING Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized dealer or other qualified service facility.

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MAINTENANCE

WHEEL REMOVAL 1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

WARNING Do not service axle nuts that have a cotter pin installed. Your authorized dealer

can assist.

5. Elevate the side of the vehicle by placing a suitable stand under the foot rest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

WHEEL INSTALLATION 1. Place the transmission in PARK.

2. Lock the parking brake.

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

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

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

WARNING Loose nuts could cause a tire to come off during operation, which could result

in an accident or overturn. Always ensure that all nuts are torqued to specification.

WHEEL NUT TORQUE SPECIFICATIONS Check the wheel nut torques occasionally and when they've been loosened for service.

WHEEL TYPE NUT TORQUE

All 75 ft-lbs (102 Nm)

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MAINTENANCE

TOE ALIGNMENT WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be

performed by an authorized POLARIS dealer or other qualified service facility.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/4-1/2 inch (6-12 mm).

1. Position the vehicle on a level surface.

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

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

4. Measure the distance from the string to the rim at the front q and rear w of the front rim. The rear measurement should be 1/81/4 inch (36 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/41/2 inch (612 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.

AIR FILTER INSTALLATION 1. Remove the seat, the air box cover strap, and remove the air box cover.

2. Remove the filter.

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

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

5. Reinstall the filter into the air box.

6. Reinstall the air box cover and the seat.

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MAINTENANCE

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

Spare fuses are provided in the fuse box.

1. Access the fuses under the front box.

2. Remove the fuse box cover.

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

4. Reinstall the fuse box cover.

5. Close and secure the front box and cover.

LIGHTS CAUTION

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and

replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility.

LED HEADLIGHT REPLACEMENT This vehicle is equipped with LED headlights. If the headlights become inoperable, the entire assembly must be replaced by your authorized Polaris dealer or other qualified service facility.

TAILLIGHT/BRAKELIGHT LAMP REPLACEMENT The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly.

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MAINTENANCE

HIGH BEAM ADJUSTMENT The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall q. Place the transmission in PARK.

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

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

4. Observe the headlight aim on the wall. The most intense part of the headlight beam should be 2 in. (5 cm) below the mark on the wallw. Include rider weight on the seat when measuring.

5. The adjustment screw is located on the left side of the headlight pod. To adjust the beam, loosen the screw. Adjust the headlamp to the desired position, then tighten the screw.

LOW BEAM ADJUSTMENT The low beam can be adjusted slightly upward or downward by rotating the adjustment screw, located on either side of the vehicle.

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MAINTENANCE

HEADLIGHT HOUSING REPLACEMENT 1. Remove the four (4) 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 the bracket for removal.

6. Reverse the steps to install the new housing and reassemble the pod.

SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the specifications section for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification.

NOTICE Using non-recommended spark plugs can result in serious engine damage.

Always use POLARIS-recommended spark plugs or their equivalent.

PLUG CONDITION TORQUE SPECIFICATION

New Spark Plug 18-20 ft-lbs (24-27 Nm)

Previously Installed Spark Plug 18-20 ft-lbs (24-27 Nm)

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

CAUTION A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

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MAINTENANCE

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Rotate the spark plug counter-clockwise to remove it.

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

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

The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments.

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

VEHICLE IMMERSION If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer can provide this service. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below.

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

2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. If equipped, remove the air box drain plug q to drain water. Reinstall the drain plug. Make sure the E-ring is on the drain plug and reinstall the drain plug.

NOTICE Serious damage could occur if the air box drain plug is not reinstalled and

tightened properly.

3. Remove the spark plugs.

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

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MAINTENANCE

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

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

NOTICE Serious damage can occur after immersion if fluids are not changed promptly.

Your authorized dealer can assist.

7. Take the vehicle in for service as soon as possible, whether you succeed in starting it or not. Your authorized dealer can provide the required service.

8. If water has been ingested into the PVT, follow the procedure in the PVT System section for drying out the PVT.

SPARK ARRESTER WARNING

Never operate the vehicle without the spark arrester. Remove any combustible materials from the area.

Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death.

Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.

Do NOT perform service on the spark arrester while the system is HOT. Exhaust system temperatures can reach extreme temperatures. Allow components to cool sufficiently before proceeding.

Do not stand behind or in front of the vehicle while purging the exhaust system.

Never go under the vehicle while it is inclined. Wear eye protection and gloves while servicing.

Periodically clean the spark arrester to remove accumulated carbon.

1. Place the transmission in PARK.

2. Remove the arrester retaining bolt and nut.

3. Remove the arrester from the end of the muffler.

4. Use non-synthetic brush to clean the arrester screen. A synthetic brush may melt if the components are warm. If necessary, blow debris from the screen with compressed air.

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MAINTENANCE

5. Inspect the screen for wear and damage. Replace a worn or damaged screen.

6. Reinstall the arrester.

7. Torque the bolt to specification.

TORQUE Spark Arrester Retaining Bolt: 911 ft. lbs. (1215 Nm)

PVT SYSTEM WARNING

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

Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following responsibilities to make sure this system remains safe:

Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.

See your POLARIS dealer, or other qualified person, for service and repair assistance.

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

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

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

On POLARIS ATVs, the approximate gear ratio difference between high and low range is 1:2.25. This difference in gearing affects the operation of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the system's dependence on engine speed.

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For example, when operating at a ground speed of 3 MPH (5 km/h) in low range, the engine speed would be around 3000 RPM. This is well above the engagement speed of 1600 - 1800 RPM. However, in high range at 3 MPH (5 km/h), the engine would be running at only 1500 RPM. Whenever operating this close to the engagement speed, the engine may be running at a speed too low to provide the pinch needed to prevent belt slip. Belt slip is responsible for creating the excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail.

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

WHEN TO USE LOW RANGE AND HIGH RANGE CONDITION RANGE TO USE

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

Low

Towing heavy loads Low

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

Low

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

High

PVT DRYING There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating.

1. Position the vehicle on a level surface.

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

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

4. Apply varying throttle for 10-15 seconds to expel the moisture and air-dry the belt and clutches. Do not hold the throttle wide open for more than 5 seconds.

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

6. Test for belt slippage. If the belt slips, repeat the process. Your vehicle requires service as soon as possible, which your authorized dealer can provide.

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BATTERY WARNING

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

battery, always connect the negative (black) cable last.

Your ATV is equipped with a sealed battery, which requires little maintenance. POLARIS does not recommend using a conventional battery in this vehicle. The orientation of the battery could result in electrolyte leakage, which would shorten the life of the battery considerably.

Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.

BATTERY REMOVAL 1. Access the battery under the front box.

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

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

4. Disconnect the battery hold-down strap.

5. Lift the battery out of the ATV.

BATTERY INSTALLATION Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the instructions in the Battery Charging section before installing the battery.

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An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, your authorized dealer can assist. Your dealer can provide any installation procedures that may differ for an extreme use battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. Coat the terminals with dielectric grease or petroleum jelly.

4. Secure the battery hold-down strap.

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

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

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

8. Close and secure the front box and cover.

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

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

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

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

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

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WARNING An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very

warm to the touch. Allow it to cool before resuming charging.

For a refresh charge, follow all instructions carefully.

1. The battery should be disconnected from a load or charger for at least two hours before checking voltage. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.6 V or higher.

2. If the voltage is less than 12.6 volts, recharge the battery at 1.2 amps or less until battery voltage is 12.6 or greater.

3. When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines via the table below.

BATTERY CHARGING (SEALED BATTERY) Always verify battery condition before and 1-2 hours after the end of charging.

STATE OF CHARGE VOLTAGE ACTION

CHARGE TIME (USING CONSTANT

CURRENT CHARGER @

STANDARD AMPS SPECIFIED ON TOP

OF BATTERY)

100% 12.6-12.8 volts Conventional/Low Maintenance Battery: check after 60 days AGM Battery: check after 30 days

None required

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 AGM ONLY: needs charge with desulfating charger

At least 20 hours

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BATTERY IDENTIFICATION IMPORTANT

It is important to identify the type of battery installed in the vehicle. Different types of batteries require different service procedures. Proper servicing and upkeep of the battery is very important for maintaining long battery life. All

Polaris ORV models include either a Conventional battery or a Low Maintenance battery.

CONVENTIONAL BATTERY The battery is NOT activated when

packaged Distilled water and electrolyte added

as required Removable cap plugs located on top

of battery Vent tube located on side of battery

LOW MAINTENANCE BATTERY Battery activated when packaged Distilled water and electrolyte

NEVER added Non removable cap(s) located on top

of battery

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MAINTENANCE

LEAD ACID CONVENTIONAL / DRY SHIPPED AGM BATTERY BEST PRACTICES Some Polaris ORV models include either a Lead Acid Conventional battery or a Dry Shipped Absorbed Glass Mat (AGM) battery. See the Service Manual for procedures on how to activate, charge, maintain, and test a Lead Acid Conventional or Dry Shipped AGM battery.

NOTICE Using a new battery that has not been fully charged can damage the battery

and result in a shorter life. It can also hinder vehicle performance.

LEAD ACID CONVENTIONAL BATTERIES ACTIVATION

NOTE A Polaris battery purchased from a Polaris dealership should be activated at

time of purchase by the dealer.

Do NOT activate the battery unless it will be put into regular service within 30 days. Bulk acid should be used to activate the battery.

Always remove the sealing cap from the vent elbow before activating the battery. Never put the sealing cap back onto the battery. The gas pressure can cause the battery to rupture.

Let the battery sit for 30 minutes after you add the initial electrolyte. Once absorbed, fill the battery with additional electrolyte to the upper line of the electrolyte level indicator. This is the only time that electrolyte should be added to the battery.

Once the battery is fully charged, replace cap plugs by hand. Do NOT use a tool to install the cap plugs.

CHARGING The battery must be fully charged before use or battery life will be significantly

reduced by 10-30% of the battery's full potential. Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls

below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.

Polaris recommends using a BatteryMINDer 12V 1.5 AMP Convertible (PN 2830511) charger (or a similar charger), which can be ordered through your normal parts channel.

Charge the battery with a charging output no larger than 10% of the batterys amp-hour rating.

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MAINTENANCE

MAINTENANCE Recharge the battery to its full capacity every 30 to 60 days. If the battery is stored or used in a partially charged condition, battery service

life and vehicle performance may be adversely affected. Never add any electrolyte to the battery once the battery is in service. After

the battery is initially activated, only distilled water should be added to maintain electrolyte levels.

Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.

TESTING If the test fails, fully charge the battery. Proper load testing of the battery requires special equipment and can be

performed by your dealer.

DRY SHIPPED AGM BATTERIES ACTIVATION Do NOT activate the battery unless it will be put into regular service within 30

days. Only use the electrolyte container supplied with the battery to activate the battery.

Keep the electrolyte container in place for 20 minutes or longer until the container is completely empty. If necessary, gently tap the container to empty it.

Once the battery is fully charged, replace the strip of caps by hand. Do NOT use a tool to install the strip.

CHARGING Polaris recommends using a BatteryMINDer 2012 AGM - 2 AMP (PN

2830438) charger, which can be ordered through your normal parts channel. Nominal voltage is 12.8 Volts when fully charged. If the voltage falls below

12.5V, charge it immediately, or the battery runs the risk of sulfation.

MAINTENANCE Never add any electrolyte or distilled water to the battery once the battery is in

service. If you do not drive the vehicle for more than TWO weeks, maintain the battery

with the BatteryMINDer 2012 AGM - 2 AMP (PN 2830438) charger. If you plan to store the vehicle for ONE month or longer, remove the battery

from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer 2012 AGM - 2 AMP (PN 2830438) charger and inspect the battery every 60 days.

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MAINTENANCE

TESTING If the test fails, fully charge the battery. If the battery is too low to accept a charge, see the AGM Battery Charging -

Deeply Discharged (Below 3 Volts) procedure in the Service Manual. Proper load testing of the battery requires special equipment and can be

performed by your dealer.

LOW MAINTENANCE BATTERY BEST PRACTICES Some Polaris ORV models include either a Lead Acid or Absorbed Glass Mat (AGM) Low Maintenance battery. See the Service Manual for procedures on how to charge, maintain, and test a Lead Acid or AGM Low Maintenance battery.

NOTICE Using a new battery that has not been fully charged can damage the battery

and result in a shorter life. It can also hinder vehicle performance.

LEAD ACID LOW MAINTENANCE BATTERY CHARGING The battery must be fully charged before use or battery life will be significantly

reduced by 10-30% of the battery's full potential. Nominal voltage is 12.6 to 12.8 Volts when fully charged. If the voltage falls

below 12.5V, charge it immediately, or the battery service life and vehicle performance may be affected.

Polaris recommends using a BatteryMINDer 12V 1.5 AMP Convertible (PN 2830511) charger (or a similar charger), which can be ordered through your normal parts channel.

Charge the battery with a charging output no larger than 10% of the batterys amp-hour rating.

MAINTENANCE Recharge the battery to its full capacity every 30 to 60 days. If the battery is stored or used in a partially charged condition, hard crystal

sulfation will form on the plates, reducing the efficiency and service life of the battery.

Never add electrolyte or distilled water to the battery. Doing so will damage the case and shorten the life of the battery.

Store the battery in the vehicle with the cables disconnected, or store the battery in a cool / dry location. Batteries will self discharge more rapidly when stored in extreme temperatures.

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TESTING Test the battery using the PU-50296 battery tester. Proper load testing of the battery requires special equipment and can be

performed by your dealer.

AGM LOW MAINTENANCE BATTERIES CHARGING Polaris recommends using a BatteryMINDer 2012 AGM - 2 AMP (PN

2830438) charger, which can be ordered through your normal parts channel. Nominal voltage is 12.612.8 Volts when fully charged. If the voltage falls

below 12.5V, charge it immediately, or the battery runs the risk of sulfation.

MAINTENANCE Never add electrolyte or distilled water to the battery. Doing so will damage

the case and shorten the life of the battery. If you do not drive the vehicle for more than TWO weeks, maintain the battery

with the BatteryMINDer 2012 AGM - 2 AMP (PN 2830438) charger. If you plan to store the vehicle for ONE month or longer, remove the battery

from the vehicle and store the battery in a cool / dry location. Continue to maintain the battery with the BatteryMINDer 2012 AGM - 2 AMP (PN 2830438) charger and inspect the battery every 60 days.

TESTING If the test fails, fully charge the battery. If the battery is too low to accept a charge, see the AGM Battery Charging -

Deeply Discharged (Below 3 Volts) procedure in the Service Manual. Proper load testing of the battery requires special equipment and can be

performed by your dealer.

CAMBER AND CASTER The camber and caster are non-adjustable.

REAR SPRING The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension.

Accessory springs are available through your POLARIS dealer.

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

4. Torque the front two bolts to specification, then torque the rear two bolts. A gap of up to 1/8" (3 mm) will remain at the rear of the clamp blocks.

TORQUE Handlebar bolts:14 ft-lbs +/- 10% (19 Nm +/- 10%)

5. Reinstall the headlight pod.

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CLEANING AND STORAGE WASHING THE VEHICLE If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and decals. Avoid directing the water stream at the following items: Wheel bearings Radiator Transmission seals Cab and body panels Electrical components Switches and controls Fuel system components Labels and decals

If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.

Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.

WASHING TIPS Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or reused

cloths and pads may contain dirt particles that will scratch the finish.

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

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.

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STORAGE TIPS NOTICE

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

storage period.

CLEAN THE EXTERIOR Make any necessary repairs and clean the vehicle as recommended. See the Washing the Vehicle section.

STABILIZE THE FUEL 1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers. Follow the instructions on the container for the recommended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.

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

OIL AND FILTER Change the oil and filter. See the Engine Oil section.

AIR FILTER / AIR BOX Replace the air filter. See Maintenance Chapter. Clean the air box.

FLUID LEVELS Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart.

Demand drive fluid (front gearcase) Rear gearcase fluid (if equipped) Transmission fluid Brake fluid (change every two years and any time the fluid looks dark or

contaminated) Coolant (test strength/fill)

INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

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FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel

treatment. Follow the instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 11.5 oz. (29.544 cc.) of engine oil. To access the plug holes, use a section of clear 6 mm (1/4) hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.

3. Reinstall the spark plugs. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap. Do not reinstall the cap onto the plug at this step.

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

6. Reinstall the spark plug caps.

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

BATTERY MAINTENANCE See the Battery Storage and Battery Charging sections for storage and charging procedures.

STORAGE AREA / COVERS Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS cover. Do not use plastic or coated materials. They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation.

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TRANSPORTING THE ATV Follow these procedures when transporting the vehicle.

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Secure the fuel cap, oil cap and seats.

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

6. Remove the key to prevent loss during transporting.

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SPECIFICATIONS SPORTSMAN 850 TRAIL

SPORTSMAN 850 TRAIL

Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories)

Dry Weight 864.07 lbs. (392 kg)

Fuel Capacity 5.25 gal. (20 l)

Engine Oil Capacity 2 qts. (1.9 l)

Coolant Capacity 2 qts. (1.9 l)

Rear Gearcase Oil Capacity 7.1 oz. (210 ml)

Demand Drive Fluid Capacity 9.3 oz. (275 ml)

Transmission Oil Capacity 37 oz. (1100 ml)

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

Rear Rack Capacity 240 lbs. (109 kg)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack load and tongue weight not to exceed 240 lbs. /109 kg)

Hitch Towing Rating 1500 lbs. (680.4 kg)

Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)

Overall Length 83.25 in. (211 cm)

Overall Width 47.6 in. (121 cm)

Overall Height 50.75 in. (129 cm)

Wheelbase 53 in. (134.6 cm)

Ground Clearance 11.6 in. (29.5 cm)

Minimum Turning Radius 84 in. (213 cm) unloaded

Engine EHO850LE

Displacement 850 cc

Bore x Stroke 87 x 71.5

Alternator Output 560w @3000 RPM

Compression Ratio 11:1

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SPECIFICATIONS

SPORTSMAN 850 TRAIL

Starting System Electric

Ignition System Electronic Fuel Injection

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

Idle RPM 1200 +/- 50

Throttle Body/Size Mikuni Dual Bore/42 mm

Spark Plug Type / Gap REA6MC / .035 in. (0.9 mm)

Lubrication System Wet Sump

Driving System Type Automatic PVT (POLARIS Variable Transmission)

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

Rear Suspension Progressive rate with 10.2" (26 cm) travel

Transmission H/L/N/R/P

Gear Reduction, Low 5.034:1

Gear Reduction, Reverse 4.508:1

Gear Reduction, High 2.367:1

Drive Ratio, Front 3.818:1

Drive Ratio, Rear 3.7:1

Tires/Pressure, Front 26x8-14 / 7 psi (48.3 kPa)

Tires/Pressure, Rear 26x10-14 / 7 psi (48.3 kPa)

Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel

Brakes, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel

Brake, Parking Hydraulic lock, all wheel

Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt)

Taillights 0.26 watts

Brake Light 3.6 watts

Instrument Cluster Digital

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SPECIFICATIONS

SPORTSMAN 850 TRAIL CLUTCHING ALTITUDE SHIFT WEIGHT DRIVE CLUTCH

SPRING DRIVEN CLUTCH SPRING

HELIX

Meters (Feet)

0-1800 (0-6000) 42-140

Purple PN 7043805

Black/White 0516_140/220 PN 7044511

64-66FR BA45 PN 32359711800-3700

(6000-12000)

SPORTSMAN XP 1000 TRAIL SPORTSMAN XP 1000 TRAIL

Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories)

Dry Weight 870.68 lbs. (395 kg)

Fuel Capacity 5.25 gal. (20 l)

Engine Oil Capacity 2 qts. (1.9 l)

Coolant Capacity 2 qts. (1.9 l)

Rear Gearcase Oil Capacity 7.1 oz. (210 ml)

Demand Drive Fluid Capacity 9.3 oz. (275 ml)

Transmission Oil Capacity 37 oz. (1100 ml)

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

Rear Rack Capacity 240 lbs. (109 kg)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack load and tongue weight not to exceed 240 lbs. /109 kg)

Hitch Towing Rating 1500 lbs. (680.4 kg)

Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)

Overall Length 83.25 in. (211 cm)

Overall Width 47.6 in. (121 cm)

Overall Height 50.75 in. (129 cm)

Wheelbase 53 in. (134.6 cm)

Ground Clearance 11.6 in. (29.5 cm)

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SPECIFICATIONS

SPORTSMAN XP 1000 TRAIL

Minimum Turning Radius 84 in. (213 cm) unloaded

Engine EHO952LE

Displacement 952 cc

Bore x Stroke 90.5 x 74

Alternator Output 560w @3000 RPM

Compression Ratio 11:1

Starting System Electric

Ignition System Electronic Fuel Injection

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

Idle RPM 1200 +/- 50

Throttle Body/Size Mikuni Dual Bore/42 mm

Spark Plug Type / Gap AUTOLITE 5682 / .030 in. (0.76 mm)

Lubrication System Wet Sump

Driving System Type Automatic PVT (POLARIS Variable Transmission)

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

Rear Suspension Progressive rate with 10.2" (26 cm) travel

Transmission H/L/N/R/P

Gear Reduction, Low 5.034:1

Gear Reduction, Reverse 4.508:1

Gear Reduction, High 2.367:1

Drive Ratio, Front 3.818:1

Drive Ratio, Rear 3.7:1

Tires/Pressure, Front 26x8-14 / 7 psi (48.3 kPa)

Tires/Pressure, Rear 26x10-14 / 7 psi (48.3 kPa)

Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel

Brakes, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel

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SPECIFICATIONS

SPORTSMAN XP 1000 TRAIL

Brake, Parking Hydraulic lock, all wheel

Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt)

Taillights 0.26 watts

Brake Light 3.6 watts

Instrument Cluster Digital

SPORTSMAN XP 1000 CLUTCHING ALTITUDE SHIFT WEIGHT DRIVE CLUTCH

SPRING DRIVEN CLUTCH SPRING

HELIX

Meters (Feet)

0-1800 (0-6000) 41-140

Purple PN 7043805

Black/White 0516_140/220 PN 7044511

64-66FR BA45 PN 32359711800-3700

(6000-12000)

SPORTSMAN XP 1000 HUNTER EDITION SPORTSMAN XP 1000 HUNTER EDITION

Maximum Weight Capacity 575 lbs. (261 kg) (includes operator, cargo and accessories)

Dry Weight 888.32 lbs. (401 kg)

Fuel Capacity 5.25 gal. (20 l)

Engine Oil Capacity 2 qts. (1.9 l)

Coolant Capacity 2 qts. (1.9 l)

Rear Gearcase Oil Capacity 7.1 oz. (210 ml)

Demand Drive Fluid Capacity 9.3 oz. (275 ml)

Transmission Oil Capacity 37 oz. (1100 ml)

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

Rear Rack Capacity 240 lbs. (109 kg)

Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack load and tongue weight not to exceed 240 lbs. /109 kg)

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SPECIFICATIONS

SPORTSMAN XP 1000 HUNTER EDITION

Hitch Towing Rating 1500 lbs. (680.4 kg)

Unbraked Trailer Towing Capacity* 1914 lbs. (868 kg)

Overall Length 83.25 in. (211 cm)

Overall Width 47.6 in. (121 cm)

Overall Height 50.75 in. (129 cm)

Wheelbase 53 in. (134.6 cm)

Ground Clearance 11.6 in. (29.5 cm)

Minimum Turning Radius 84 in. (213 cm) unloaded

Engine EHO952LE

Displacement 952 cc

Bore x Stroke 90.5 x 74

Alternator Output 560w @3000 RPM

Compression Ratio 11:1

Starting System Electric

Ignition System Electronic Fuel Injection

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

Idle RPM 1200 +/- 50

Throttle Body/Size Mikuni Dual Bore/42 mm

Spark Plug Type / Gap AUTOLITE 5682 / .030 in. (0.76 mm)

Lubrication System Wet Sump

Driving System Type Automatic PVT (POLARIS Variable Transmission)

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

Rear Suspension Progressive rate with 10.2" (26 cm) travel

Transmission H/L/N/R/P

Gear Reduction, Low 5.034:1

Gear Reduction, Reverse 4.508:1

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SPECIFICATIONS

SPORTSMAN XP 1000 HUNTER EDITION

Gear Reduction, High 2.367:1

Drive Ratio, Front 3.818:1

Drive Ratio, Rear 3.7:1

Tires/Pressure, Front 26x8-14 / 7 psi (48.3 kPa)

Tires/Pressure, Rear 26x10-14 / 7 psi (48.3 kPa)

Brakes, Front/Rear Single-Control Hydraulic Disc, All Wheel

Brakes, Auxiliary Foot-Activated Hydraulic Disc, Rear Wheel

Brake, Parking Hydraulic lock, all wheel

Headlight 1 Single Beam on Headlight Pod (50 watt) 2 Single Beam on Bumper (50 watt)

Taillights 0.26 watts

Brake Light 3.6 watts

Instrument Cluster Digital

SPORTSMAN XP 1000 CLUTCHING ALTITUDE SHIFT WEIGHT DRIVE CLUTCH

SPRING DRIVEN CLUTCH SPRING

HELIX

Meters (Feet)

0-1800 (0-6000) 41-140

Purple PN 7043805

Black/White 0516_140/220 PN 7044511

64-66FR BA45 PN 32359711800-3700

(6000-12000)

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SPECIFICATIONS

134

POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS

PRODUCT SIZE (QUANTITY) PART NUMBER

Fogging Oil 12 oz aerosol (12) 2870791

1 qt (12) 2871517

PS-4

1 qt (12) 2876244

2 qt (8) 2877490

1 gal (4) 2876245

PS-4 Extreme Duty

1 qt (12) 2878920

2 qt (8) 2878922

1 gal (4) 2878919

AGL 1 qt (12) 2878068

1 gal (4) 2878069

Pump for Gallon Jug 3.8 l 2870465

Demand Drive 1 qt (12) 2877922

2.5 gal (2) 2877923

Antifreeze / Coolant 1 qt (12) 2880514

1 gal (6) 2880513

Grease Gun Kit, Premium All Season 2871312

All Season Grease Four 3 oz packs (6) 2871322

14 oz cartridge 2871423

Premium Starter Grease 2871460

U-Joint Grease 3 oz tube (24) 2871515

14 oz cartridge 2871551

Dielectric Grease (Nyogel) 2871329

Carbon Clean 12 oz bottle (12) 2871326

Fuel Stabilizer 16 oz (12) 2870652

2.5 gal (2) 2872280

DOT 4 Brake Fluid 2872189

Loctite 565 Thread Sealant 2871956

POLARIS Battery Tender Charger 2859044

135

POLARIS PRODUCTS

136

TROUBLESHOOTING DRIVE BELT WEAR/BURN

POSSIBLE CAUSE SOLUTION

Driving onto a pickup or tall trailer in high range Use low range during loading.

Starting out going up a steep incline Use low range.

Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently.

Insufficient warm-up at low ambient temperatures

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

Slow/easy clutch engagement Use the throttle quickly and effectively.

Towing/pushing at low RPM/ low ground speed Use low range only.

Utility use/plowing Use low range only.

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. Prevent water from entering the PVT intake duct. See Intake Pre-Filters for more information. Inspect clutch seals for damage if repeated leaking occurs.

Clutch malfunction An authorized dealer can assist.

Poor engine performance Check for fouled plug or foreign material in gas tank or fuel lines. An authorized dealer can assist.

Slippage from failure to warm up belt

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

Wrong or missing belt Install the recommended belt.

Improper break-in Always break in a new belt and/or clutch.

137

TROUBLESHOOTING

ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION

Low battery voltage Recharge the battery to 12.8 VDC

Loose battery connections Check all connections and tighten

Loose solenoid connections Check all connections and tighten

Loose electronic control box connections

Inspect, clean, reinstall connectors

ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Water is present in fuel Drain the fuel system and refuel

Old or non-recommended fuel Replace with fresh recommended fuel

Fouled or defective spark plug Inspect plug and replace if necessary

No spark to spark plug Inspect plug and replace if necessary

Water or fuel in crankcase Your authorized dealer can assist

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure Your authorized dealer can assist

ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION

Weak spark from spark plug Inspect, clean and/or replace spark plug

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

Old or non-recommended fuel Replace with fresh recommended fuel

Incorrectly installed spark plug wires

Your authorized dealer can assist

Mechanical failure Your authorized dealer can assist

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with fresh recommended fuel

138

TROUBLESHOOTING

ENGINE PINGS OR KNOCKS POSSIBLE CAUSE SOLUTION

Poor quality or low octane fuel Replace with recommended fuel

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES

POSSIBLE CAUSE SOLUTION

Fouled or defective spark plug Inspect, clean and/or replace spark plug

Worn or defective spark plug wires

Your authorized dealer can assist

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with new fuel

Low battery voltage Recharge battery to 12.8 VDC

Incorrect fuel Replace with recommended fuel

Clogged air filter Inspect and clean or replace

Clogged intake pre-filter Inspect and clean (with soapy water) or replace

Other mechanical failure Your authorized dealer can assist

ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Kinked or plugged fuel vent line

Inspect and replace

Water is present in fuel Replace with new fuel

Fouled or defective spark plug Inspect, clean and/or replace spark plug

Worn or defective spark plug wires

Your authorized dealer can assist

Incorrect spark plug gap or heat range

Set gap to specs or replace plug

139

TROUBLESHOOTING

POSSIBLE CAUSE SOLUTION

Loose ignition connections Check all connections and tighten

Low battery voltage Recharge the battery to 12.8 VDC

Incorrect fuel Replace with fresh recommended fuel

Clogged air filter Inspect and clean or replace

Clogged intake pre-filter Inspect and clean (with soapy water) or replace

Other mechanical failure Your authorized dealer can assist

Overheated engine Clean radiator screen and core, clean engine exterior. Your dealer can assist.

140

TROUBLESHOOTING

WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, or other qualified person, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.

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

141

WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.

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

Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Filters Lubricants Bushings

Finished and unfinished surfaces Carburetor/Throttle body

components Engine components Drive belts Hydraulic components and fluids Circuit breakers/Fuses Electronic components Spark plugs Sealants Coolants Bearings

142

WARRANTY

LUBRICANTS AND FLUIDS 1. Mixing oil brands or using non-recommended oil may cause engine damage.

We recommend the use of POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

143

WARRANTY

HOW TO OBTAIN WARRANTY SERVICE If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service.

IN THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer, or other qualified person. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer, or other qualified person, that sells the same line as your product.

OUTSIDE THE COUNTRY WHERE YOUR PRODUCT WAS PURCHASED: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer, or other qualified person. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair.

IF YOU MOVE: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your product.

IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

144

WARRANTY

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

NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Dealership contacts can be found via this website, if needed:

www.polaris.com/en-us/contact Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

145

WARRANTY

U.S.A. EPA EMISSIONS LIMITED WARRANTY This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations.

The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension.

This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions, and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited warranty does not cover components whose failure does not increase the vehicle's regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

Air-induction system Fuel system

Ignition system Exhaust gas recirculation systems

The following parts are also considered emission-related components for exhaust emissions:

Aftertreatment devices Crankcase ventilation valves

Sensors Electronic control units

146

WARRANTY

The following parts are considered emission-related components for evaporative emissions:

Fuel Tank Fuel Cap Fuel Line Fuel Line Fittings Clamps* Pressure Relief Valves* Control Valves* Control Solenoids* Electronic Controls*

Vacuum Control Diaphragms* Control Cables* Control Linkages* Purge Valves Vapor Hoses Liquid/Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector

*As related to the evaporative emission control system.

Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance. The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire, explosions or other similar causes beyond the control of POLARIS.

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WARRANTY

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance or use, by accidents for which POLARIS has no responsibility, or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on your vehicle. An authorized POLARIS dealer, or other qualified person, can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

CALIFORNIA RESIDENTS Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are certified for sale in California. The 50- state models available for sale in California are identified by the letter B in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer.

If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

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WARRANTY

MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

149

MAINTENANCE LOG

150

2X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 850 Trail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

A Active Descent Control (ADC) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

ADC 4X4 Mode . . . . . . . . . . . . . . . . . . . . . . . . . 37 Age 16 Warning . . . . . . . . . . . . . . . . . . . . . . . . 23 Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 13 Air Filter / Air Box. . . . . . . . . . . . . . . . . . . . . 124 Air Filter Installation . . . . . . . . . . . . . . . . . 106 All Wheel Drive System. . . . . . . . . . . . . . . 37 Automatic Transmission Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Auxiliary Foot Brake . . . . . . . . . . . . . 33, 103 AWD Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

B Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Identification. . . . . . . . . . . . . . . . . . . . . . . . . 117 Battery Charge Port . . . . . . . . . . . . . . . . . . . 36 Battery Charging . . . . . . . . . . . . . . . . . . . . . . 115 Battery Installation . . . . . . . . . . . . . . . . . . . . 114 Battery Maintenance . . . . . . . . . . . . . . . . 125 Battery Removal. . . . . . . . . . . . . . . . . . . . . . . 114 Battery Storage . . . . . . . . . . . . . . . . . . . . . . . . 115 Bluetooth Operation . . . . . . . . . . . . . . . . . . . 51 Boots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Brake Fluid Level. . . . . . . . . . . . . . . . . . . . . . . 33 Brake Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Brake System Break-in . . . . . . . . . . . . . . . 60 Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

C Camber and Caster. . . . . . . . . . . . . . . . . . 121 Cargo Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 74 Clean the Exterior . . . . . . . . . . . . . . . . . . . . 124 Cleaning and Storage. . . . . . . . . . . . . . . 123 Clothing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Clutch Cover Warning. . . . . . . . . . . . . . . . . 25

Cold Weather Operation. . . . . . . . . . . . . . 64 Cooling System. . . . . . . . . . . . . . . . . . . . . . . 101 Crankcase Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Crossing Hillsides . . . . . . . . . . . . . . . . . . . . . . 17

D Descending Hills Improperly . . . . . . . . 16 Diagnostic Display Code Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Digital Gauge. . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Discretionary Warning . . . . . . . . . . . . . . . . 23 Disengaging Active Descent Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Drive Belt Wear/Burn. . . . . . . . . . . . . . . . 137 Driving in Reverse . . . . . . . . . . . . . . . . . . . . . 71 Driving on a Sidehill (Sidehilling) . . . 68 Driving on Slippery Surfaces . . . . . . . . 66 Driving Over Obstacles . . . . . . . . . . . . . . . 70 Driving Through Water. . . . . . . . . . . . . . . . 69 Driving Uphill . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

E Electromagnetic Interference . . . . . . . 87 Electronic Power Steering (EPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35-36

Emissions Limited Warranty. . . . . . . 146 Engaging 4X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Engaging Active Descent Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Engine and Drivetrain Break-in . . . . . 60 Engine Backfires . . . . . . . . . . . . . . . . . . . . . 138 Engine Doesn't Turn Over . . . . . . . . . 138 Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Engine Pings or Knocks . . . . . . . . . . . . 139 Engine Runs Irregularly, Stalls or Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Engine Stop Switch. . . . . . . . . . . . . . . . . . . . 28 Engine Stopping. . . . . . . . . . . . . . . . . . . . . . . . 72 Engine Stops or Loses Power . . . . 139 Engine Turns Over, Fails to Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

European Vibration and Noise . . . . . . . . 9

151

Exhaust Emission Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Exported Products . . . . . . . . . . . . . . . . . . . 145 Exposure to Exhaust . . . . . . . . . . . . . . . . . . 14 Extreme Use Battery . . . . . . . . . . . . . . . . . . 36 Eye Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 12

F Failure to Inspect Before Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Fluid Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Fluid Part Numbers . . . . . . . . . . . . . . . . . . 135 Fog the Engine . . . . . . . . . . . . . . . . . . . . . . . 125 Front Compartment. . . . . . . . . . . . . . . . . . . . 35 Front Gearcase (Demand Drive) Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Front Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Front Wheel Hub Tightening . . . . . . 104 Fuel Cap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . 124 Fuse Replacement. . . . . . . . . . . . . . . . . . . 107

G General Warning . . . . . . . . . . . . . . . . . . . . . . . 24 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

H Hand Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103 Handlebars . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122 Handling Gasoline . . . . . . . . . . . . . . . . . . . . . 14 Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Headlight Housing Replacement . . . . . . . . . . . . . . . . . . . . . . . . 109

Headlight Switch . . . . . . . . . . . . . . . . . . . . . . . 29 Helmet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 High Beam Adjustment . . . . . . . . . . . . . 108 Hot Exhaust Systems . . . . . . . . . . . . . . . . . 21 How To Obtain Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

I Ignition Switch/Light Switch . . . . . . . . . 27 Improper Cargo Loading . . . . . . . . . . . . . 20 Improper Hill Climbing . . . . . . . . . . . . . . . . 16 Inspect and Lubricate . . . . . . . . . . . . . . . 124 Instrument Cluster

Back Light Color . . . . . . . . . . . . . . . . . . . . . 49 Back Light Level . . . . . . . . . . . . . . . . . . . . . 50 Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Diagnostic Code. . . . . . . . . . . . . . . . . . . . . 53 Display Area 1 . . . . . . . . . . . . . . . . . . . . . . . 42 Display Area 2 . . . . . . . . . . . . . . . . . . . . . . . 43 Indicator Lamps . . . . . . . . . . . . . . . . . . . . . 40 Options Menu . . . . . . . . . . . . . . . . . . . . . . . . 45 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Service Hours . . . . . . . . . . . . . . . . . . . . . . . . 51 Unit Selection Distance. . . . . . . . . . . . 46 Unit Selection Temperature. . . . . . . 47

J Jumps and Stunts . . . . . . . . . . . . . . . . . . . . . . 16

K Know Your Riding Area/Tread Lightly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

L Lead Acid Conventional Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Lead Acid Low Maintenance Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

LED Headlight Replacement . . . . . . 107 Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Limited Warranty . . . . . . . . . . . . . . . . . . . . . 141 Low Beam Adjustment . . . . . . . . . . . . . . 108 Lubricants / Service Products . . . . . 135 Lubrication Guide . . . . . . . . . . . . . . . . . . . . . . 93

M Maintenance Chart Key . . . . . . . . . . . . . . 90

152

Maintenance Log. . . . . . . . . . . . . . . . . . . . . 149 Master Cylinder/Brake Fluid. . . . . . . . . 31 Mode/Reverse Override Switch . . . . 28 Modifications to Vehicle . . . . . . . . . . . . . . 21

N New Operator Driving Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

No Passenger Warning . . . . . . . . . . . . . 24 Noise Emission Control System. . . . 87

O Oil and Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Oil and Filter Change. . . . . . . . . . . . . . . . . . 96 Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 Oil Recommendations . . . . . . . . . . . . . . . . 94 Operating at Excessive Speeds . . . . 15 Operating Improperly in Reverse. . . 18 Operating in Unfamiliar Terrain . . . . . 18 Operating on Frozen Bodies of Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operating on Pavement . . . . . . . . . . . . . . 15 Operating on Public Roads . . . . . . . . . . 15 Operating on Slippery Terrain . . . . . . . 18 Operating on Steep Hills . . . . . . . . . . . . . 18 Operating Over Obstacles . . . . . . . . . . . 19 Operating Through Water . . . . . . . . . . . . 19 Operating With a Passenger . . . . . . . . 15 Operation on Public Lands in the U.S.A.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

P Parking Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Parking on an Incline . . . . . . . . . . . . . . . . . . 72 Parking the Vehicle . . . . . . . . . . . . . . . . . . . . 73 Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 135 Periodic Maintenance . . . . . . . . . . . . . . . . . 89 Physical Control of the Vehicle . . . . . 16 Physical Skills. . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Polaris Products . . . . . . . . . . . . . . . . . . . . . . 135 Polishing the Vehicle . . . . . . . . . . . . . . . . 123 Poor Visibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Power Steering Unit (Cleaning). . . 101 Pre-Ride Checklist . . . . . . . . . . . . . . . . . . . . . 61 Protective Apparel . . . . . . . . . . . . . . . . . . . . . 14 PVT Break-in (Clutches/Belt) . . . . . . . 60 PVT System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

R Rack/Box Warning . . . . . . . . . . . . . . . . . . . . . 24 Radiator Coolant . . . . . . . . . . . . . . . . . . . . . 102 Rear Gearcase Oil . . . . . . . . . . . . . . . . . . . 100 Rear Spring. . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Recovery Bottle Coolant . . . . . . . . . . . 102 Registration, Warranty . . . . . . . . . . . . . . 141 Reverse Override Warning/ AWD Caution . . . . . . . . . . . . . . . . . . . . . . . . . . 23

S Safe Operation Practices . . . . . . . . . . . . 62 Safe Riding Gear. . . . . . . . . . . . . . . . . . . . . . . 11 Safety Labels and Locations . . . . . . . . 22 Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Safety Training. . . . . . . . . . . . . . . . . . . . . . . . . . 11 Safety Warnings. . . . . . . . . . . . . . . . . . . . . . . . 13 Safety, Winch Maintenance. . . . . . . . . . 86 Seat Removal . . . . . . . . . . . . . . . . . . . . . . . . . 103 Severe Use Definition. . . . . . . . . . . . . . . . . 89 Shock Loading the Winch . . . . . . . . . . . . 85 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Skidding or Sliding . . . . . . . . . . . . . . . . . . . . . 19 Spark Arrester . . . . . . . . . . . . . . . . . . . . . . . . . 111 Spark Plug Inspection. . . . . . . . . . . . . . . 109 Spark Plug Recommendations . . . 109 Spark Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Specifications . . . . . . . . . . . . . . . . . . . 127, 129 Specifications (Hunter Edition) . . . 131 Stabilize the Fuel . . . . . . . . . . . . . . . . . . . . . 124 Stalling While Climbing a Hill . . . . . . . . 17 Starting the Engine . . . . . . . . . . . . . . . . . . . . 64 Steering Assembly. . . . . . . . . . . . . . . . . . . 101 Stopping the Engine. . . . . . . . . . . . . . . . . . . 72 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

153

T Taillight/Brakelight Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . 107

Throttle Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Tire Pressure/Load Warning (Hunter Models). . . . . . . . . . . . . . . . . . . . . . . 25

Tire Pressure/Load Warning (Trail Models) . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Tire Tread Depth . . . . . . . . . . . . . . . . . . . . . 104 Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Toe Alignment. . . . . . . . . . . . . . . . . . . . . . . . . 106 Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Trademarks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Trail Etiquette . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Transmission Oil. . . . . . . . . . . . . . . . . . . . . . . . 98 Transporting the ATV. . . . . . . . . . . . . . . . 126 Turning Around on a Hill (K- Turn) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Turning Improperly. . . . . . . . . . . . . . . . . . . . . 16

U Unauthorized Use of the Vehicle . . . 21

V Vehicle Break-in Period. . . . . . . . . . . . . . . 59 Vehicle Identification Numbers . . . . . . . 9 Vehicle Immersion . . . . . . . . . . . . . . . . . . . . 110

W Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . 8 Washing the Vehicle. . . . . . . . . . . . . . . . . 123 Wet Fouled Plug. . . . . . . . . . . . . . . . . . . . . . . 110 Wheel Installation . . . . . . . . . . . . . . . . . . . . 105 Wheel Nut Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . 105

Wheel Removal. . . . . . . . . . . . . . . . . . . . . . . 105 Winch Cable Care . . . . . . . . . . . . . . . . . . . . . 84 Winch Maintenance and Service Safety . . . . . . . . . . . . . . . . . . . . . . . . . 86

Winch Operation . . . . . . . . . . . . . . . . . . . . . . . 79 Winch Safety Precautions . . . . . . . . . . . 77 Winch Shock Loading. . . . . . . . . . . . . . . . . 85

X XP 1000 Trail. . . . . . . . . . . . . . . . . . . . . . . . . . 129

154

WARNING Improper ATV use can result in SEVERE INJURY or Death

NEVER USE ON PUBLIC

ROADS

NEVER CARRY PASSENGERS

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE

GEAR

NEVER USE WITH DRUGS OR ALCOHOL

NEVER operate:

ALWAYS:

overturns on hills and rough terrain and in turns

affect handling and control

SCAN CODE FOR PRODUCT AND SAFETY INFORMATION. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

r your skills or the condi

Manualsnet FAQs

If you want to find out how the XP 1000 Polaris works, you can view and download the Polaris Sportsman 850 Trail Edition v2 Owner's Manual on the Manualsnet website.

Yes, we have the Owner's Manual for Polaris XP 1000 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 XP 1000. Full manuals and user guide PDFs can be downloaded from Manualsnet.com.

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This Polaris Sportsman 850 Trail Edition v2 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.

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