Polaris General 1000 EPS, 1000 EPS Deluxe Owner's Manual PDF

Pages 146
Year 2020
Language(s)
English en
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Summary of Content for Polaris General 1000 EPS, 1000 EPS Deluxe Owner's Manual PDF

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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...

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For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owners manual... Review the safety DVD that came with your vehicle... POLARIS also recommends that all drivers take the ROHVA safety e-course and a ROHVA hands-on safety training course... Visit www... rohva... org or call 866-267-2751...

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Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 51 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 67 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 77 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 79 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 119 POLARIS Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 121 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 123 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 127 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 137

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Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death... Your POLARIS vehicle is not a toy and can be hazardous to operate... This vehicle handles differently than cars, trucks or other off-road vehicles... A collision or rollover can occur quickly, even during

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SAFETY SYMBOLS AND SIGNALWORDS 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...

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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

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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...

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We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual... This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals...

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The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time... The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow... Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow...

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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...

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

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Fasten seat belts... Wear an approved helmet and protective gear... ALWAYS use cab nets and/or doors... Each rider must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel or hand holds... Stay completely inside the vehicle...

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CLUTCH COVERWARNING (7177469) The clutch cover warningq is located on the clutch cover... WARNING Improper service or maintenance of this PVTsystem can result in vehicle damage, SEVERE INJURYor DEATH... Always look for and remove debris inside and around clutch and vent system when replacing belt... Read owners manual or see authorized POLARIS dealer...

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Read Operation and Maintenance Manual for more detailed loading information...

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INTAKE ALERT (7185975) Use a Polaris approved air filter... The use of a non-Polaris approved air filter may cause engine damage... Before installing filter ensure there is no dirt or debris in the clean side of the intake tube... The air filter must be properly seated and the hinges fully inserted when the lid is reinstalled... Please reference your owners manual for additional information regarding the air filter service... Label Location: on the air box...

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TIRE PRESSURE / PASSENGER ALERT (7190997) Never carry passengers in cargo box... Passengers can be thrown off... This can cause serious injury or death... Read owners manual... Never carry or transport fuel on this vehicle... The Tire Pressure / Passenger Alert decal is located on the front panel of the rear cargo boxq...

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GENERAL 4 272 kg Occupants: 4 (Driver + 3 Passengers) Weight: 580 kg

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No person under the age of 12 may ride as a passenger in this vehicle... All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold...

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Always place the transmission in PARK before getting out of the vehicle... Always stop the engine before refueling... Remove flammable material containers from the box before filling them with fuel... Make sure the refueling area is well ventilated and free of any source of flame or sparks... Gasoline is extremely flammable... See the Refueling section for fuel safety warnings...

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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...

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CAB DOORS Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover... Always make sure all cab doors are closed and latched while riding in this vehicle... Cab doors are NOT intended to be used as arm rests... Always keep hands and feet inside the vehicle at all times...

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Do not exceed vehicle weight capacities... The vehicles maximum weight capacity is listed in the specifications section of this manual and on a label on 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...

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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...

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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...

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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

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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

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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

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q Console w Headlights e Radiator r Front Bumper/ Brush Guard tMuffler (Spark Arrester) y CV Boot/Rear Caliper

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GEAR SELECTOR Low gear is the primary driving range for your vehicle... High gear is intended for use on hard-packed surfaces with light loads... Using high gear for heavy loads, hilly terrain or in wet, muddy conditions will increase the chance of drive belt burning... See the Drive Belt Wear/Burn section on page 123...

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The engine is off... Powers the gauge and terminal block... Check engine and steering warning indicators will appear on the gauge in this mode, but will turn off when the vehicle is started if no issues are present...

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LIGHT SWITCH The ignition switch key must be in the ON/RUN position to operate the headlights... Press the top of the switch to place the headlights on high beam... Move the switch to the center position to place the headlights on low beam... Press the bottom of the switch to turn off the headlights...

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THROTTLE PEDAL Push the throttle pedalw down to increase engine speed... Spring pressure returns the pedal to the rest position when released... Always check that the throttle pedal returns normally before starting the engine...

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This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers... Always make sure the seat belts are secured for all riders before operating... The drivers seat belt is equipped with a seat belt interlock... Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured...

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SEATAND STORAGE COMPARTMENTS A small storage compartment is located behind the passenger seatq... If your model is equipped with a storage console and cup holders located between the seats, lift the console lid to access the storage compartment... The ECU is located in the compartment behind the drivers seat... Do not use this area for storage... The electrical compartment is located under the drivers seat... Never use the electrical compartment for storage... Remove the drivers seat to access the battery and fuse box...

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ELECTRONIC POWER STEERING (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position... EPS remains engaged whether the vehicle is moving or idle... To conserve battery power, the EPS will shut down 5 minutes after the engine is stopped if the key remains in the ON position... The EPS warning indicator will illuminate to indicate the EPS has shut down... Turn the key off and on to reset the unit... If the light remains on after starting the engine, the EPS system is inoperative... See your POLARIS dealer, or other qualified person, as soon as possible for repair... Continued operation could result in permanent damage to the EPS unit and increased steering effort...

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The fuel tank filler capq is located on the right side of the vehicle near the passenger seat... Use only unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane (equivalent to 95 RON in Europe)... Unleaded fuel blends with up to 10% ethanol can be used...

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

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TOGGLE BUTTONS Press and release either toggle buttont to cycle through the options menu or Area 2 modes... Press and hold either toggle button to reset an item... See page 45...

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This indicator illuminates briefly when the key is turned to the ON position... If the light remains on, the EPS system is inoperative... See your POLARIS dealer, or other qualified person, as soon as possible for repair... Continued operation could result in permanent damage to the EPS unit and increased steering effort...

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The rider information center is located in the instrument cluster... All segments will light up for one second at start-up... If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer... If this occurs, your POLARIS dealer, or other qualified person, can provide proper diagnosis... The information center is set to display standard units of measurement and a 12-hour clock at the factory... To change to metric and/or a 24-hour clock hold the mode button and cycle to the clock menu... Use the directional arrows to change the clock settings...

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Trip Meters (T1/T2) A trip meter records the distance traveled by the vehicle if reset before each trip... To reset, see page 47...

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ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays... See the Mode Information Displays section for details...

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4... Press either toggle button to change each segment of the clock... Press MODE to accept a change and advance to the next segment...

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PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory... As hours of engine operation increase, the counter decreases... The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset...

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When this feature is enabled, it provides a convenient reminder to perform routine maintenance... Refer to the Periodic Maintenance Chart for recommended service intervals...

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ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator is on or when it goes on and off during one ignition cycle... Error codes are not stored... When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine...

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VEHICLE BREAK-IN PERIOD The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 full tanks of gasoline... No single action on your part is as important as a proper break-in period... Careful treatment of a new engine will result in more efficient performance and longer life for the engine... Perform the following procedures carefully...

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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...

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

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

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In some situations, the front gearcase may remain locked after turning the AWD switch off... If this occurs, you may notice increased steering effort and some vehicle speed restriction... Perform the following procedure to unlock the front gearcase...

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UNLOCKING THE DIFFERENTIAL (TURF MODE) When operating in TURF mode, the inside rear wheel will rotate independently from the outside wheel during turns... Operate in TURF mode only as needed to protect smooth, level surfaces from tire damage... DO NOToperate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings... Always operate in AWD on these types of terrain...

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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, passengers, non-factory installed 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...

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Your POLARIS vehicle has been designed to carry or tow specific capacities... Always read and understand the load distribution warnings listed on the warning labels... The total load (operator, passengers, non-factory installed accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle... See the Safety chapter for details...

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6... Avoid towing loads on an incline... If its unavoidable, choose the smallest incline available, operate with extreme caution, and drive straight up or down the incline...

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WARNING Operating the vehicle while the cargo box is raised could result in severe injury... The box could close unexpectedly and cause injury to the driver or passenger... The rear tires could also catch the rear of a raised box, damaging the vehicle and creating hazardous driving conditions... Never operate this vehicle with the

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If towing a disabled vehicle is unavoidable, place the disabled vehicles transmission in neutral... Tow the shortest distance possible... Do not operate faster than 10 MPH (16 km/h)...

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7... Slow down... Always travel at a speed appropriate for your skills, your passengers skills, and operating conditions... Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger...

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When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding... Follow these precautions when encountering slippery conditions:

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5... If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill...

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NOTE After running your vehicle in water, it's critical that you perform the services outlined in the Periodic Maintenance Chart section... Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all

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2... 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...

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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...

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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...

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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...

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

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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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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 74... For your safety, always follow these guidelines when winching a vehicle free:

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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...

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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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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...

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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 NOTalike... A polymer rope not designed for winch use will stretch and store excessive energy when winching...

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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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MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle... An authorized 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...

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

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Change fluid every 25 hours if ADC is subjected to extreme use... See the Front Gearcase section for details...

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Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every 2 years

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LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, or more often under severe use, such as wet or dusty conditions... Items not listed in the chart should be lubricated at the general lubrication interval...

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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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8... Remove the oil fill capw to add the recommended oil as needed... Maintain the oil level between the minimum and maximum marks on the dipstick... Do not overfill...

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6... Carefully detach the fuel line and spark plug wires from their retaining clips on the outlet hose, then loosen the outlet hose clamp and remove the hose from the clutch cover...

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22... Reinstall the outlet hose to the clutch box, routing the hose under the fuel line and spark plug wires... Make sure the clutch cover rib aligns in the notch at the end of the outlet hose... Tighten the clamp...

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GEARCASES TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart section... Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications... See page 121 for the part numbers of POLARIS products...

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FRONT GEARCASE Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart... Maintain the oil level even with the bottom thread of the fill plug hole... Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications... See page 121 for the part numbers of POLARIS products...

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GEARCASE SPECIFICATION CHART GEARCASE LUBRICANT CAPACITY FILL PLUG

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

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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: incorrect spark plug type or heat range, excessive engine oil consumption or incorrect throttle body adjustments...

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RADIATOR AND COOLING FAN Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart... Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan... Interference with the radiator air flow can lead to overheating and consequent engine damage...

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5... Reinstall the pressure cap securely... Use of a non-standard pressure cap will not allow the recovery system to function properly... Your POLARIS dealer, or other qualified person, can provide the correct replacement part...

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system has been precision balanced... Any modification will cause the system to be out of balance, creating vibration and additional loads on components... The PVTsystem rotates at high speeds, creating large amounts of force on clutch components... As the owner, you have the following responsibilities for

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TIP Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail... Switch to low range while operating at slower speeds to extend the life of the PVTcomponents

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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 arease thoroughly...

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FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart... Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle for extended periods...

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

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store or use a partial bottle... 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

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Do not apply WD-40 or any petroleum product to brake discs... These types of products are flammable and may also reduce the friction between the brake

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SUSPENSION SETTINGS (EPS) FRONT/REAR SPRING PRELOAD (EPS) The front and rear suspensions are preload adjustable, with five possible settings... The suspensions are set on the lowest setting at the factory... The factory setting is appropriate for nearly all riding conditions...

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FRONT/REAR SHOCK COMPRESSION The compression damping clicker knob is located at the top of the shock reservoir... When the knob is turned fully clockwise, the damping is in the fully closed position...

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Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death... Always replace tires when the tread depth measures 3 mm (1/8) or less... Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury... Always maintain proper tire pressure... Always use POLARIS

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handling, which can result in serious injury or death... Always ensure that all nuts are torqued to specification... Do not service axle nuts that have a cotter pin

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FUSES 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... Raise the drivers seat to access the fuses... Spare fuses are provided in the fuse box... The power steering fuse (if equipped) is located on the power steering wiring harness near the fuse box...

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LIGHTS Poor lighting can result in reduced visibility when driving... Headlight and taillight lenses become dirty during normal operation... Clean lights frequently and replace burned out lamps promptly... Do not operate this vehicle at night or in low light conditions until the headlight is replaced... Always make sure lights are adjusted properly for best visibility...

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5... Observe the headlight aim... The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall... Include the weight of a rider on the seat while performing this step...

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Your vehicle has a low-maintenance battery... Always keep battery terminals and connections free of corrosion... If cleaning is necessary, remove the 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...

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The single most important thing about maintaining a sealed battery is to keep it fully charged... Check the battery voltage with a voltmeter or multimeter... A fully charged battery will register 12... 8 V or higher... If the voltage falls below 12... 5V, charge it immediately, or the battery runs the risk of sulfation and reduced battery life...

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If using a constant current charger (instead of BatteryMINDer 2012 AGM - 2 AMP charger), use the guidelines below... Always verify battery condition before and 1-2 hours after the end of charging...

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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...

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If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer, or other qualified person, to purchase a replacement... Replacement safety labels are provided by POLARIS at no charge...

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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...

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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...

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1... Check the battery electrolyte level and charge the battery if necessary... Install it in the vehicle... Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way...

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Overall Length 116 in... (294... 6 cm) (EPS) 118 in... (299... 7 cm) (EPS w/Winch and Aluminum Wheels) 118 in... (299... 7 cm) (EPS Deluxe)

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CLUTCHING (GENERAL) See your POLARIS dealer or qualified person for clutching specifications...

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POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS

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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...

Page 126

Fouled or defective spark plug Inspect plug and replace if necessary

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Clogged intake pre-filter Inspect and clean (with soapy water) or replace

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Overheated engine Clean radiator screen and core, clean engine exterior... Your POLARIS dealer, or other qualified person, can assist

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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...

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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...

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THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OFANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTYARE 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 OFANY 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...

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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...

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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...

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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...

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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 WARRANTYARE 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 OFANY 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...

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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...

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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...

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OWNER'S WARRANTY RESPONSIBILITIES: As the OHRV-EVAP owner, you are responsible for the performance of the required maintenance listed in your owner's manual... Polaris recommends that you retain all receipts covering maintenance on your OHRV-EVAP, but Polaris cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of a scheduled maintenance... As an owner you are responsible for presenting your OHRV-EVAP to a Polaris dealer as soon as a problem exists... The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days... As an OHRV-EVAP owner, you should also be aware that Polaris may deny you warranty coverage if your OHRV-EVAP or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications...

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MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance...

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E Electromagnetic Interference ... 77 Electronic Power Steering ... 38 Emissions Limited Warranty... 132 Engine Backfires ... 124 Engine Break-In ... 51 Engine Doesn't Turn Over ... 124 Engine Oil ... 84 Engine Oil Change... 86 Engine Oil Check... 85 Engine Pings or Knocks ... 125 Engine Runs Irregularly, Stalls or Misfires ... 125 Engine Stopping... 52 Engine Turns Over, Fails to Start ... 124 Error Codes, Engine... 49 European Vibration and Noise ... 9 Exhaust Emission Control System ... 77 Exhaust System Warning ... 99 Exported Products ... 131 Eye Protection ... 13

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Fluid Levels... 116 Fluid Part Numbers ... 121 Fog the Engine ... 116 Fouled Plugs ... 92 Front Gearcase ... 89 Fuel Cap... 39 Fuel Safety... 25 Fuel Stabilizer... 115 Fuses ... 107

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S Safe Riding Gear... 12 Safety Labels... 14 Safety Symbols ... 8 Safety Training... 11 Safety Warnings... 51 Safety, Winch Maintenance... 75 Seat Belt... 36 Seat Belts ... 24 Seat Removal ... 37 Shift Alert (7183987) ... 19 Shifter ... 32 Shock Compression (EPS Deluxe) ... 104 Shock Loading the Winch ... 74 Signal Words ... 8 Spark Arrester ... 99 Spark Plug Inspection... 91 Spark Plug Recommendations ... 91 Specifications ... 119 Spring Preload (EPS Deluxe) ... 103 Spring Preload (EPS) ... 103 Stabilize the Fuel ... 115 Stalling While Climbing a Hill ... 28 Starting the Engine ... 52 Steering Wheel Inspection... 98 Steering Wheel, Adjustment... 38 Stopping the Engine... 52 Storage ... 115 Storage Area ... 116 Storage Compartment Access... 37 Storage Compartment, Under- Seat ... 37 Suspension Settings (EPS Deluxe) ... 103 Suspension Settings (EPS)... 103 Switches... 33 Ignition Switch ... 33

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T Tachometer ... 41 Throttle Pedal ... 35 Tire Pressure / Passenger Alert (7190997) ... 19 Tire Tread Depth ... 105 Tires ... 105 Torque, Axle Nuts ... 105 Torque, Spark Plug ... 91 Torque, Wheel Nut ... 105 Towing Loads ... 59 Towing the GENERAL ... 61 Trailer Hitch Bracket... 38 Transmission ... 88 Drying ... 97 Oil ... 88

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For your nearest Polaris dealer, call 1-800-POLARIS (765-2747)

Manualsnet FAQs

If you want to find out how the General 1000 EPS Polaris works, you can view and download the Polaris General 1000 EPS, 1000 EPS Deluxe Owner's Manual on the Manualsnet website.

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