Contents

Polaris PRO XD 2000D 4X2, 2000D AWD, 4000D AWD Owners Manual Owner's Manual PDF

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Summary of Content for Polaris PRO XD 2000D 4X2, 2000D AWD, 4000D AWD Owners Manual Owner's Manual PDF

POLARIS PRO XD 2000D 4x2

POLARIS PRO XD 2000D AWD

POLARIS PRO XD 4000D AWD

Owner's Manual

For Maintenance and Safety

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 expect 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.

!

2019 Owners Manual

POLARIS PRO XD 2000D 4x2 POLARIS PRO XD 2000D AWD POLARIS PRO XD 4000D AWD

POLARIS and PRO XD 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. 9930762 Rev 01

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.

Snowmobiles SPORTSMAN All-terrain vehicles GEM vehicles and other low emission vehicles (LEVs)

RANGER utility vehicles SLINGSHOT three wheel motorcycles

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

Timbersled Snow Bikes

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.

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

4

WELCOME

Introduction . . . . . . . . . . . . . . . . . . . . 7 Safety . . . . . . . . . . . . . . . . . . . . . . 11 Features and Controls . . . . . . . . . . . . . . 29 Operation . . . . . . . . . . . . . . . . . . . . 57 Winch Guide. . . . . . . . . . . . . . . . . . . 83 Emission Control Systems . . . . . . . . . . . . . 93 Maintenance . . . . . . . . . . . . . . . . . . 95 Specifications . . . . . . . . . . . . . . . . . . 159 POLARIS Products . . . . . . . . . . . . . . . . 163 Troubleshooting . . . . . . . . . . . . . . . . . 165 Warranty . . . . . . . . . . . . . . . . . . . . 171 Maintenance Log . . . . . . . . . . . . . . . . 183

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6

INTRODUCTION WARNING

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

This vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles. A collision or rollover can occur quickly, even

during routine maneuvers, if you fail to take proper precautions.

Read this owners manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle at all times.

This vehicle is an ADULT VEHICLE ONLY. You MUST be at least 16 years of age and have a valid drivers license to operate this vehicle.

No person under the age of 12 may ride as a passenger in this vehicle. Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels.

Always keep hands, feet, and all other body parts inside the vehicle at all times.

Always wear the proper clothing when operating or riding in this vehicle. All riders should wear substantial footwear, long pants, and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for riding or working conditions.

Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time.

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

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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 SAFETYALERT WARNING indicates a hazardous situation which, if not

avoided, COULD result in serious injury or death.

CAUTION SAFETYALERT 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

VEHICLE IDENTIFICATION NUMBERS Record your vehicle's identification numbers in the spaces provided. The engine serial number is located on the side of the engine, below the injection pump. All keys have the number 4083. Remove the spare key and store it in a safe place. Additional pre-cut keys for your vehicle can be ordered.

Vehicle Model Number

Vehicle Identification Number (VIN) q

Engine Serial Numberw

Key Number 4083

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INTRODUCTION

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SAFETY PERSONAL PROTECTIVE EQUIPMENT Always wear the proper clothing when operating or riding in this vehicle. All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions. POLARIS recommends wearing approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE. Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes. Workplace safety regulations may require the use of safety glasses, safety shoes and a hard hat or helmet. Familiarize yourself with local requirements, be prepared for operating conditions and wear the appropriate safety gear.

RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area. 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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SAFETY

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. 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.

The seat belt/drive responsibly warning labelq and the proper use warning labelw are located on the front ROPS, above the drivers head.

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SAFETY

SEAT BELT / DRIVE RESPONSIBLY WARNING WARNING IMPROPER VEHICLE USE CAN RESULT IN SERIOUS INJURY OR DEATH NEVER OPERATE:

At speeds too fast for your skills or the conditions. After or while using Alcohol or Drugs. Across slopes (Avoid side hilling). On public roads. This vehicle is for off-highway use only. Driving on public roads could be a violation of law and may be hazardous.

On paved surfaces - pavement can alter handling and may cause loss of control.

With more passengers than described in the Operation & Maintenance Manual, with children under the age of 12, and passengers who cannot comfortably reach the floor and hand holds with back against the seat.

With unapproved accessories - they may seriously affect stability.

LOCATE AND READ OPERATION & MAINTENANCE MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS:

Wear head protection - such as a hard hat or helmet - as appropriate for conditions and usage. Consult manual for more information.

Wear your seatbelt. Vehicle rollover could cause serious injury or death. Wear eye protection and keep hands and feet in vehicle at all times. Reduce speed and use extra caution when carrying passengers. Avoid sharp turns or turns while applying heavy throttle. Operate slowly in reverse - avoid sharp turns or sudden braking. Make sure passengers read and understand all warning labels. Watch for branches or other hazards that could enter vehicle.

Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll, reduce your risk to injury:

Keep a firm grip on the steering wheel or handholds and brace yourself. Do not put any part of your body outside of the vehicle for any reason.

Rollovers have caused severe injuries and death, even on flat, open areas.

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SAFETY

PROPER USE WARNING (2000D) WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries:

Do not allow careless or reckless driving. Make sure operators are 16 or older with a valid drivers license. Do not let people drive or ride after using alcohol or drugs. Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

Do not exceed seating capacity: 2 occupants.

PROPER USE WARNING (4000D) WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries:

Do not allow careless or reckless driving. Make sure operators are 16 or older with a valid drivers license. Do not let people drive or ride after using alcohol or drugs. Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

Do not exceed seating capacity: 4 occupants.

FUEL TRANSPORT WARNING The fuel transport warning labelq is located in the cargo box. WARNING NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.

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SAFETY

LOAD/PASSENGER/TIRE PRESSURE WARNING The load/passenger/tire pressure warning label is located next to the fuel transport warning label in the cargo box.

WARNING FALLING OFF CARGO BOX CAN CAUSE SERIOUS INJURY OR DEATH

Never carry riders in cargo box.

OVERLOADING OR IMPROPER TIRE PRESSURE CAN CAUSE TIPPING OR LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH

Never exceed load capacities. Reduce speed and allow greater distance for braking when carrying cargo. Carrying tall, off-center, or unsecured loads will increase your risk of losing control. Center and secure loads as low as possible in box.

Reduce speed and cargo on rough or hilly terrain. Check for proper tire pressures.

MODEL NUMBER 2000D 4000D

MAXIMUM CARGO BOX LOAD

1250 lbs. (566 kg)

1250 lbs. (566 kg)

TIRE PRESSURE IN PSI (KPa)

FRONT 24 (165) FRONT 24 (165)

FRONT 24 (165) FRONT 24 (165)

VEHICLE RATED CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO, AND ACCESSORIES.

1900 lbs. (861 kg)

2075 lbs. (941 kg)

Read Operation & Maintenance Manual for more detailed loading information.

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SAFETY

CLUTCH COVER WARNING 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.

SHIFT CAUTION The shift cautionq is located above the ignition switch.

CAUTION To avoid transmission damage, shift only when vehicle is stationary and at idle. When vehicle is stopped, place gear selector in PARK.

PULLEY WARNING The pulley warningq is located on the rear frame.

WARNING Moving parts present. Keep hands away from moving parts to prevent injury.

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SAFETY

BELT WARNING 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.

TRAILER/HITCH CAPACITY LABEL The trailer/hitch capacity label is located on the rear hitch bracket.

CAUTION HOT SURFACE. DO NOT TOUCH. TRAILER MAX. WEIGHT: 2500 LBS. (1134 kg) HITCH MAX. VERTICALWEIGHT: 250 LBS. (114 kg)

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SAFETY

OPERATOR SAFETY WARNING

Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual.

Read this entire manual and all labels carefully. Follow the operating procedures described.

Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

No person under the age of 12 may ride as a passenger in this vehicle. Always keep hands and feet inside the vehicle at all times. Always keep both hands on the steering wheel (driver) and both feet on the floorboards of the vehicle during operation.

Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels.

Always make sure the seat belts are secured for operator and passenger before operating.

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

Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

Always use the proper size and type of tires specified in this manual. Always maintain proper tire pressure as specified on safety labels.

Never modify this vehicle through improper installation or use of non- POLARIS-approved accessories.

Always set the park brake and remove the key when leaving the vehicle unattended.

Never consume alcohol or drugs before or while operating this vehicle. Never operate at excessive speeds. Always operate at a speed that's appropriate for the traffic, the visibility and operating conditions, your skills and your passengers skills.

Always inspect the vehicle before each use to make sure it's in safe operating condition. Always follow the inspection procedures described in this manual.

Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

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SAFETY

Always follow proper procedures for turning. Make turns slowly, especially when the ground is wet, greasy, bumpy or sloping. Never turn the steering wheel abruptly when driving at high speed.

Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.

Always be alert for obstacles when operating this vehicle. Never attempt to operate over obstacles.

Never operate this vehicle on steep hills. Never operate on excessively rough, slippery or loose terrain. Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

Always be sure there are no obstacles or people behind your vehicle when operating in reverse. When it's safe to proceed in reverse, move slowly. Avoid turning at sharp angles in reverse.

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.

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. See the Operation

chapter of this 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.

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SAFETY

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.

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 outlined in the Operation chapter 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. See the Periodic Maintenance section of the Maintenance

chapter.

SEAT BELTS WARNING

Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances. The

operator MUSTwear the seat belt at all times.

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SAFETY

OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.

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.

The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle.

Always follow these guidelines:

UNDER ANY OF THESE CONDITIONS: DO ALL OF THESE STEPS:

Operator and/or cargo exceeds half the maximum weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Operating in rough terrain

Operating over obstacles

Climbing an incline

Towing

IMPROPER TIRE MAINTENANCE WARNING

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 AT EXCESSIVE SPEEDS CAUTION

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

JUMPS AND STUNTS CAUTION

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

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.

IMPROPER HILL CLIMBING CAUTION

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.

DESCENDING HILLS IMPROPERLY CAUTION

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.

CROSSING HILLSIDES CAUTION

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.

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SAFETY

STALLING WHILE CLIMBING A HILL CAUTION

Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.

If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

If you begin rolling downhill:

Never apply engine power. Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

OPERATING IN UNFAMILIAR TERRAIN CAUTION

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

CAUTION Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause

loss of control or rollover.

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

OPERATING IMPROPERLY IN REVERSE CAUTION

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual.

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

SKIDDING OR SLIDING CAUTION

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.

CAUTION 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.

OPERATING OVER OBSTACLES CAUTION

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.

OPERATING THROUGH WATER CAUTION

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. Wet brakes will 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

OPERATING ON FROZEN BODIES OF WATER WARNING

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.

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.

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.

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.

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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. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush, and other tall ground cover. Promptly

remove any grass or debris clinging to the vehicle.

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.

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.

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SAFETY

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

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FEATURES AND CONTROLS COMPONENT LOCATIONS

q Console tMuffler (Spark Arrester)

w Headlights y Receiver Hitch

e Radiator u CV Boot / Rear Caliper

r Front Bumper / Brush Guard

i ROPS Cab Frame o Cargo Box a Tailgate s Fuel Cap

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FEATURES AND CONTROLS

CONSOLE

q Cup Holder u Horn Switch

w Light Switch i 4x2 Differential Lock Switch (if equipped)

e Instrument Cluster o Drivers Side Auxiliary Outlet

r Ignition Switch a Passenger Side Auxiliary Outlet

t Gear Selector (Shifter) s Storage Compartment

y Park Brake

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FEATURES AND CONTROLS

AUXILIARY OUTLETS The auxiliary outlets can be used to power standard 12V accessories like a cell phone charger or a power inverter up to 120 watts. The drivers side auxiliary outlet is always on, even when the vehicle is switched off and the key is removed. This drivers side outlet is always on so that a battery maintainer may be connected to maintain the battery while the vehicle is in storage. The passenger side outlet (and the rear outlet on 4000D models) switches on and off with the vehicle. These outlets cannot be used to charge the battery because they disconnect when the vehicle is off. 4000D models have a third auxiliary outlet on switched power located in the center console between the rear seats.

ADJUSTABLE STEERING WHEEL The steering wheel can be tilted upward or downward for rider preference. Lift and hold the adjustment leverq toward you while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

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FEATURES AND CONTROLS

GEAR SELECTOR Low gear is the primary driving range for the PRO XD. 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 spinning. An alarm will sound if the vehicle detects belt spin. See the Drive Belt Wear/Spin section on page 165. H: High Gear

L: Low Gear

N: Neutral

R: Reverse

P: Park

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

NOTICE Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. Always shift when the vehicle is stationary

and the engine is at idle.

TIP Maintaining shift linkage adjustment is important to assure proper transmission

function. See your dealer if you experience any shifting problems.

USING LOW RANGE Always shift into low gear for any of the following conditions.

Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads Driving frequently at low RPM or at ground speeds below 11 km/h (7 MPH)

REVERSE ALERT BEEPER Putting the vehicle into reverse will automatically activate the reverse alert beeper.

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FEATURES AND CONTROLS

PARK BRAKE LEVER Always apply the service brakes before engaging or releasing the park brakeq. To help prevent the vehicle from rolling, set the park brake when parking the vehicle. When the park brake is set and the park brake indicator is illuminated, an alarm will sound if pressure is put on the throttle pedal.

TIP This feature will not operate properly if the park brake connector or switch

(under the hood) malfunctions or becomes disconnected, or if the switch has moved. Check for disconnection, then see your dealer or other qualified

service person promptly if this feature fails to operate properly.

1. To set the park brake, apply the brakes. Pull the park brake lever towards yourself as far as possible.

2. To release the park brake, apply the brakes. Turn the park brake lever counterclockwise and push it in as far as possible.

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FEATURES AND CONTROLS

SWITCHES IGNITION SWITCH The ignition switch is a three-position, key-operated switch. The key can be removed from the switch when it is in the OFF position.

OFF The engine is off. Electrical circuits are off, except for the drivers side auxiliary outlet and the Pulse Bar.

ON Vehicle is on. All electrical equipment can be used. When first keyed on, glow plugs activate for 12 seconds and then deactivate. The indicator on the gauge displays when glow plugs are active.

START Turn the key to the START position to engage the starter. The key returns to the ON position when released.

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.

34

FEATURES AND CONTROLS

4X2 DIFFERENTIAL LOCK SWITCH (IF EQUIPPED) NOTE

Only 2000D 4x2 models will have a Differential Lock switch.

The Differential Lock switch has two positions: Differential Lock/Two Wheel Drive (2WD) and Turf Mode. Press the top of the switch to engage Two Wheel Drive (2WD). Press the bottom of the switch to unlock the differential and operate in Turf Mode.

PULSE BAR The Pulse Bar is located under the hood and can be used to connect any Pulse Bar accessory to the vehicle. The Pulse Bar receives constant and switched power from the battery, so that accessories may be powered whether the vehicle is on or off.

35

FEATURES AND CONTROLS

FOOT PEDALS

BRAKE PEDAL Depress the brake pedalq to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel.

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.

36

FEATURES AND CONTROLS

SEAT AND STORAGE COMPARTMENTS The electrical compartment is located under the center rear-most seat. Never use this area for storage. Storage compartments are located under all other seats. Remove the storage bin under the right rear-most passenger seat to access the battery. Always make sure all seats are properly installed before operating. Push down firmly on the rear of each seat until the latch pins are fully seated into the grommets.

DRIVERS SEAT To access the storage area under the drivers seat, reach behind the drivers seat and pull up on the latch. Roll the bottom of the seat forward toward steering wheel.

PASSENGERS SEAT To access the storage area under the passenger seat, lift up on the front of the passenger seat and raise it to the upright position.

ELECTRONIC POWER STEERING (EPS) (IF EQUIPPED)

NOTE Only 4000D models have Electronic Power Steering.

Electronic power steering 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. 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.

BELT SPIN ALARM The Belt Spin Alarm will sound if the vehicle senses or detects belt spin (engine RPM without ground speed).

37

FEATURES AND CONTROLS

FUEL CAP The fuel tank filler capq is located on the left-hand side of the vehicle near the drivers seat. Use only the recommended diesel fuel.

OCCUPANT PROTECTION STRUCTURE (OPS) The Occupant Protection Structure (OPS) on this vehicle meets ANSI/OPEI B71.9 standards. Always have your authorized dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING Vehicle rollover could cause severe injury or death. Always avoid operating in

a manner that could result in vehicle rollover.

HOOD LATCHES To remove the hood, rotate the hood latchesq 1/4-turn and lift the hood away from the vehicle.

TRAILER HITCH BRACKET This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle. To avoid injury and property damage, always heed the warnings and towing capacities.

38

FEATURES AND CONTROLS

SEAT BELTS This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats. Always make sure the seat belts are secured for all riders before operating.

WARNING Falling from a moving vehicle could result in serious injury or death. Always

fasten your seat belt securely before operating or riding.

To wear the seat belt properly, follow this procedure:

1. For 3-point belts with D loopsw, pull the seat belt latch downward and across your chest toward the buckle q at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self-tighten.

4. To release the seat belt, press the square red button in the buckles center.

SEAT BELT INSPECTION Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.

39

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 Differential Lock/ Turf Mode Indicator (4x2 models only)

Segments of the indicator illuminate based on drive mode engaged.

40

FEATURES AND CONTROLS

INDICATOR LAMPS

q Check Engine

This lamp illuminates when the ECM detects a Diagnostic Trouble Code in the engine management system. Do not operate the vehicle if this warning appears. Serious engine damage could result. Your authorized POLARIS dealer can assist. This lamp will also illuminate if the vehicle is keyed on but not started; it will turn off once the vehicle is started.

w EPS Warning (if equipped)

This lamp illuminates to indicate that EPS has shut down. EPS shuts down automatically 5 minutes after the engine is turned off if the key remains in the ON position. Turn the key off and on to reset the unit. If the light remains on after starting the engine, the EPS system is inoperative. Your POLARIS dealer can assist.

e Engine Hot

This lamp illuminates to indicate an overheated engine. If the indicator flashes, a severe overheating condition exists and the engine will shut down automatically. The vehicle will not start again until the engine has sufficiently cooled down. Whenever this lamp illuminates, the engine load should be reduced in any way possible to avoid overheating and shutting down the engine.

r Low Oil Pressure

This lamp illuminates if engine oil pressure drops below safe operating pressure. If this lamp illuminates while the engine is running, turn the engine off as soon as safely possible

41

FEATURES AND CONTROLS

and check the oil level. If the oil level is correct and the lamp remains on after the engine is restarted, turn the engine off immediately.

t Seat Belt

This lamp flashes for several seconds when the key is turned to the ON position. The lamp will keep flashing as long as riders seat belts are not connected.

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

u Park Brake Indicator

This lamp illuminates when the park brake is active.

i Glow Plug Indicator

This lamp illuminates when the glow plugs are active.

42

FEATURES AND CONTROLS

DISPLAY AREA 1

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

Speed Engine Temperature

RPM Ambient

Temperature (Optional)

43

FEATURES AND CONTROLS

DISPLAY AREA 2

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

Odometer Engine Temperature

Trip 1 Ambient

Temperature (Optional)

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

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)

eWith 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)

eWith 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)

eWith 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)

tWith 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)

uWith 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)

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

48

FEATURES AND CONTROLS

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.

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)

eWith 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)

eWith 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)

eWith 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.

51

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.

52

FEATURES AND CONTROLS

DIAGNOSTIC DISPLAY CODE DEFINITIONS DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Low oil pressure switch fault

CAN message 65390 Timeout error 100 11

Current below normal or open circuit 100 5

Engine Temperature Sensor

Voltage above normal, or shorted to high source

110 3

Voltage above normal, or shorted to high source

110 4

System Power (Battery Potential/ Power Input)

Data valid but below normal operational range - most severe level

168 1

Voltage above normal, or shorted to high source

168 3

Voltage below normal, or shorted to low source

168 4

Gear Sensor Signal Voltage below normal, or shorted to low source

523 4

Rear Differential Output

Voltage above normal, or shorted to high source

746 3

Voltage below normal, or shorted to low source

746 4

Current below normal or open circuit 746 5

Fan Relay Driver Ckt. Voltage above normal, or shorted to high source

1071 3

Voltage below normal, or shorted to low source

1071 4

Current below normal or open circuit 1071 5

53

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Fuel Pump Driver Ckt. Voltage above normal, or shorted to high source

1347 3

Voltage below normal, or shorted to low source

1347 4

Current below normal or open circuit 1347 5

ECU Output Supply Voltage 1

Voltage above normal, or shorted to high source

3597 3

Voltage below normal, or shorted to low source

3597 4

ECU Output Supply Voltage 3

Voltage above normal, or shorted to high source

3598 3

Voltage below normal, or shorted to low source

3598 4

All Wheel Drive Control Circuit

Voltage above normal, or shorted to high source

520207 3

Voltage below normal, or shorted to low source

520207 4

Current below normal or open circuit 520207 5

Brake failure lamp faults

Voltage above normal, or shorted to high source

520214 3

Voltage below normal, or shorted to low source

520214 4

Current below normal or open circuit 520214 5

Glow Plug Relay Driver Circuit

Voltage above normal, or shorted to high source

520272 3

Voltage below normal, or shorted to low source

520272 4

54

FEATURES AND CONTROLS

DIAGNOSTIC CODES

COMPONENT CONDITION SPN FMI

Current below normal or open circuit 520272 5

Brake switch (1 or 2 indeterminable)

Data erratic, intermittent or incorrect

520285 2

Engine Oil Pressure Sensor

Data valid but below normal operating range - least severe level

524076 17

55

FEATURES AND CONTROLS

56

OPERATION 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 vehicle is the first 50 hours of operation. 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.

NOTICE Excessive heat build-up during the first 3 hours of operation will damage close- fitted engine parts and drive components. Do not operate at full throttle or high

speeds during the first 3 hours of use.

ENGINE AND DRIVETRAIN BREAK-IN 1. Fill the fuel tank with clean, fresh fuel.

2. Check the oil level. Add the recommended oil as needed to maintain the oil level in the safe operating range.

3. Complete the New Operator Driving Procedures.

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 50 hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 50 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.

57

OPERATION

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.

SAFE OPERATION PRACTICES 1. Do not allow anyone under 16 years of age or without a valid drivers license

to operate this vehicle.

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

3. Never operate with accessories not approved by POLARIS for use on this vehicle.

4. 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.

5. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel or handlebars during operation.

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

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

8. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.

9. 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.

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

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

58

OPERATION

PRE-RIDE INSPECTION WARNING

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

before each use to make sure it's in safe operating condition.

ITEM REMARKS PAGE

Brake system/pedal travel Ensure proper operation page 142

Brake fluid Ensure proper level page 142

Front suspension Inspect, lubricate if necessary page 113

Rear suspension Inspect, lubricate if necessary page 113

Steering Ensure free operation -

Tires Inspect condition and pressure page 144

Wheels/fasteners Inspect, ensure fastener tightness page 144

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Drive Belt Inspect, ensure installed correctly -

Fuel and oil Ensure proper levels page 113

Coolant level Ensure proper level page 123

Coolant hoses Inspect for leaks -

Air Filter Inspect, clean as necessary, ensure proper installation

page 134

Throttle Ensure proper operation page 36

Indicator lights/switches Ensure proper operation page 41 page 34

Intake drain Inspect, clean, drain as needed -

Headlamps Check operation, apply POLARIS dielectric grease when lamp is replaced

page 147

Brake light/tail lamps Check operation -

Seat Latch Push down on the seat back to ensure the latch is secure

-

Seat Belt Check length of belt for damage, check latches for proper operation

page 39

59

OPERATION

ITEM REMARKS PAGE

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

-

Park Brake Ensure proper operation page 33

60

OPERATION

FUEL RECOMMENDATIONS NOTICE

For the best engine performance, to prevent engine damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel

fuels. Use only CLEAN diesel fuel.

POLARIS recommends the following diesel fuels for use in this vehicle:

Ultra Low Sulfur #2 #1 Diesel Fuel containing no more than 20% bio-diesel

For more information about recommended diesel fuels and the consequences of using bio-diesel fuel exceeding 20% bio- diesel, see Additional Technical Fuel Requirements below.

Diesel fuel should comply with the following world-wide specifications.

DIESEL FUEL SPECIFICATION LOCATION

ASTM D975 No. 1D S15, S500 No. 2D S15, S500

USA

EN590:96 European Union

ISO 8217 DMX International

BS 2869-A1 or A2 United Kingdom

JIS K2204 Grade No. 2 Japan

KSM-2610 Korea

GB252 China

61

OPERATION

ADDITIONAL TECHNICAL FUEL REQUIREMENTS The fuel cetane number should be equal to 45 or higher. The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Especially in the U.S.A. and Canada, Ultra Low Sulfur fuel should be used.

Bio-Diesel fuels. NEVER mix kerosene, used engine oil or residual fuels with diesel fuel. Water and sediment in the fuel should not exceed 0.05% by volume. Keep the fuel tank and fuel-handling equipment clean at all times. Poor quality fuel can reduce engine performance and/or cause engine damage.

Fuel additives are not recommended. Some fuel additives may cause poor engine performance.

Ash content must not exceed 0.01% by volume. Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred.

Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test analysis method JPI-5S-44-95).

Lubricity: Wear mark of WS1.4 should be Max. 460m (0.018 in.) at HFRR test.

62

OPERATION

BIO-DIESEL FUELS In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels. These B20 diesel fuels must meet certain requirements:

1. The bio-fuels must meet the minimum specifications for the country in which they are used. In Europe, bio-diesel fuels must comply with the European Standard EN14214.

In the United States, bio-diesel fuels must comply with the American Standard ASTMD-6751.2.

2. Bio-fuels should be purchased only from recognized and authorized diesel fuel suppliers.

Precautions and concerns regarding the use of bio-fuels:

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.

2. Free water in FAME may result in plugging of fuel filters and increased bacterial growth.

3. High viscosity at low temperatures may result in fuel delivery problems, injection pump seizures and poor injection nozzle spray atomization.

4. FAME may have adverse effects on some elastomers (seal materials) and may result in fuel leakage and dilution of the engine lubricating oil.

5. Even bio-diesel fuels that comply with a suitable standard as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system and/or fuel storage containers may be necessary.

6. The use of bio-diesel fuels that do not comply with the standards as agreed to by the diesel engine manufacturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

B21 To B100 Bio-diesel Fuel Blend Usage

B21 to B100 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the Kubota engine series listed below may operate with bio-diesel fuel concentrations up to B20 for POLARIS applications.

63

OPERATION

NOTICE Do not exceed bio-diesel fuel blend B20 for this POLARIS application.

Kubota D902

Approved Fuel

NOTICE Raw pressed vegetable oils are not considered bio-diesel, and are unacceptable for use as fuel in any concentration in Kubota engines.

Bio-diesel fuel blends up to B20 must comply with the following standards:

EN14214 (European standard) and/or ASTM D-6751 (American standard). All applicable engines may operate with bio-diesel fuel up to a maximum B20 (20% bio- diesel blend) concentration.

Operating Conditions with B20 Bio-diesel Fuel Blends

Engine Warranty Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty. The same applies to damages or other concerns induced by not complying with the recommended operating conditions of Kubota engines with bio-diesel fuel.

64

OPERATION

HANDLING FUEL WARNING

Diesel fuel is flammable and explosive under certain conditions.

NEVER refuel with the engine running. Always refuel outdoors or in a well ventilated area. Fill the fuel tank with diesel fuel ONLY. Filling the fuel tank with gasoline may result in a fire and will damage the engine.

Remove flammable material containers from the box before filling them with fuel.

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

Wipe up all spills immediately. Keep sparks, open flames or any other form of ignition (match, cigarette, static electricity source) well away when refueling.

NEVER remove the fuel cap while the engine is running. NEVER overfill the fuel tank. Do not fill the tank neck. If fuel spills on your skin or clothing, immediately wash it off with soap and water and change clothing.

REFUELING The fuel tank filler cap is located on the left side of the vehicle near the drivers seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill.

65

OPERATION

COLD WEATHER OPERATION Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the following fuel blending guideline to prevent this from occurring.

FUEL BLENDING GUIDELINE

Temperature No. 2 No. 1

-9 C (+15 F) 100% 0%

Down to -29 C (-20 F) 50% 50%

Below -29 C (-20 F) 0% 100%

COLD STARTING GUIDELINES

Temp. -7 C to -9 C

(+20 F to +15 F)

-9 C to -15 C

(+15 F to +5 F)

-15 C to -29 C (+5 F to -20 F)

-29 C to -32 C

(-20 F to -25 F)

Fuel #2 Diesel 50/50 mix #1/#2 diesel #1 Diesel

5W-40 Synthetic Diesel

Engine Oil

Optional Advised Required

Block heater Optional Advised Required

Battery condition/ connections

Charged battery (12.8 VDC)

Proper glow plug usage (wait for the

light)

Wait for light at all temps

Oil pan heater

Not needed Optional (helps to reduce cranking)

BLOCK HEATER USE If this vehicle will be operated when temperatures are in the -15 to -32 C (+5 to -25 F) range, a block heater must be installed. Please see your dealer to purchase a block heater kit.

66

OPERATION

NOTE Block heater is not recommended when the vehicle is operated above -4 C

(+25 F).

BIO-DIESEL BLENDED FUEL NOTICE

Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle.

Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle:

Cold weather conditions can lead to plugged fuel system components and hard starting.

Bio-diesel blended fuel is an excellent medium for microbial growth and contamination which can cause corrosion and plugging of fuel system components.

Use of bio-diesel blended fuel may result in premature failure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

Shorter maintenance intervals may be required, such as cleaning the fuel system and replacing fuel filters and fuel lines.

Using bio-diesel blended fuels containing more than 20% bio-diesel can affect engine life and cause deterioration of hoses, tubes, injectors, injector pump and seals.

Use the following guidelines if bio-diesel blended fuel is used:

Never use bio-diesel blended fuel containing more than 20% bio-diesel in this vehicle.

Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank.

Ensure that the fuel tank cap is securely tightened. Clean up any spilled fuel immediately to prevent damage to painted surfaces. Drain all water from the fuel filter daily before operating the vehicle. Do not exceed the engine oil change interval. Extended intervals can result in engine damage.

Before vehicle storage, drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTICE Bio-diesel blended fuel does not have long term stability and should not be

stored for more than three months.

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OPERATION

OPERATING CONDITIONS NOTICE

Observe the following environmental operating conditions to maintain engine performance and avoid premature engine wear.

Avoid operating in the presence of chemical gases or fumes. Avoid operating in a corrosive atmosphere such as salt water spray. NEVER operate the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood.

NEVER expose the engine to the rain. The standard range of ambient temperatures for the normal operation of Kubota engines is from -15 C (+5 F) to +40 C (+104 F).

If the ambient temperature exceeds +40 C (+104 F), the engine may overheat and cause the engine oil to break down.

If the ambient temperature is between -15 C (+5 F) and -32 C (-25 F), POLARIS recommends the use of a block heater.

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OPERATION

STARTING THE ENGINE NOTICE

NEVER use an engine starting aid such as ether. Engine damage will result.

Before operating this vehicle in cold weather, review the cold weather operation information on the preceding pages. Always wait for the glow plug indicator light to turn off before cranking the engine.

1. Always start the engine outdoors or in a well-ventilated area.

2. Sit in the driver's seat and fasten the seat belt.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the engine.

5. Turn the ignition switch to the ON position and wait for the glow plug indicator light to turn off.

6. Turn the ignition key past the ON position to START. Engage the starter for a maximum of five seconds. Release the key when the engine starts.

7. If the engine does not start within five seconds, release the ignition switch and wait five seconds. Repeat steps 6 and 7 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.

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OPERATION

STOPPING THE ENGINE For maximum engine life, allow the engine to idle, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down.

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

2. Place the transmission in PARK.

3. Engage the park brake.

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

5. Turn the engine off and remove the key to prevent unauthorized use.

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

PARK and engage the park brake when stopping the engine.

BRAKING 1. Release the throttle pedal completely.

TIP When the throttle pedal is released completely and the engine speed drops

near an idle, the vehicle has no engine braking.

2. Press on the brake pedal evenly and firmly.

TIP If the throttle pedal and brake pedal are applied simultaneously, engine power

may be limited.

3. Practice starting and stopping (using the brakes) until youre familiar with the controls.

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OPERATION

REAR DIFFERENTIAL SYSTEM (IF EQUIPPED) The Polaris PRO XD 2000D 4x2 is equipped with a lockable differential. You can choose to operate with an open differential or a closed differential.

LOCKING THE DIFFERENTIAL Move the rocker switch to the top position to lock the differential and operate in two wheel drive (2WD). Locking the differential in slippery or low traction conditions helps improve traction. When the rear differential is locked, both rear wheels rotate at the same speed.

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.

WARNING Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches

the ground again.

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD). When the rear differential is unlocked, the rear wheels can rotate at different speeds. Unlock the differential to make maneuvering easier and minimize damage to turf.

NOTICE Damage to the differential can occur if it is engaged while the vehicle is

traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.

WARNING Never operate in TURF mode (if equipped) while operating on a hill or other

irregular terrain.

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OPERATION

DRIVING PROCEDURES 1. All riders should wear substantial footwear, long pants and a close-fitting

shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions.

2. Perform the pre-ride inspection.

3. Sit in the driver's seat and fasten the seat belt.

4. Place the transmission in PARK.

5. Engage the park brake.

6. Start the engine.

7. Apply the service brakes and shift the transmission into gear.

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

9. Release the park brake.

10.Keeping both hands on the steering wheel, slowly release the brakes and slowly depress the throttle with your right foot to begin driving.

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

12.Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

3. All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye protection are recommended when appropriate for working or riding conditions.

4. Do not carry more than the recommended number of passengers for your vehicle.

5. Allow a passenger to ride only in a passenger seat.

6. 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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OPERATION

7. Vehicle handling may change with a passenger and/or cargo on board. Allow more time and distance for braking.

8. Always follow all operating guidelines as outlined on safety labels and in this manual.

DRIVING ON SLIPPERY SURFACES WARNING

Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose

gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

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:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down before entering slippery areas.

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

4. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

DRIVING UPHILL Whenever traveling uphill, follow these precautions:

1. Avoid excessively steep hills.

2. Always travel straight uphill.

3. Keep both feet on the floor.

4. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces.

5. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly.

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

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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 rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

DRIVING DOWNHILL When driving downhill, follow these precautions:

1. Avoid excessively steep hills.

2. Always descend a hill with the direction selector switch on forward. Never descend a hill with the switch on neutral.

3. Drive straight downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible.

4. Slow down.

5. Apply the brakes slightly to aid in slowing.

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OPERATION

DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboardsq.

NOTICE Immersion can result in major damage if the vehicle isn't serviced correctly and promptly. After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined in the Vehicle Immersion

section, and take the vehicle to your dealer at the first opportunity.

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. Proceed slowly, avoiding rocks and obstacles.

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

WARNING The large tires on your vehicle may cause the vehicle to float in deep or fast- flowing water, which could result in loss of control and lead to serious injury or

death. Never cross deep or fast-flowing water with your vehicle

5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

NOTE After running your vehicle in water, it's critical that you perform the services

outlined in the Periodic Maintenance Chart. Give special attention to engine oil, transmission oil, front and rear gearcases (if equipped), and all grease fittings.

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OPERATION

DRIVING IN REVERSE NOTICE

Shifting into reverse automatically activates the reverse alert beeper.

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing.

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.

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. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

5. Always have all passengers dismount and move away from the vehicle before operating over an obstacle that could cause a rollover.

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OPERATION

PARKING THE VEHICLE To park the vehicle, do the following:

1. Apply the brakes. Stop the vehicle on a level surface.

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.

3. Place the transmission in PARK.

4. Turn the engine off.

5. Engage the park brake.

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

7. Remove the ignition switch key to prevent unauthorized use.

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Engage the park brake.

4. Turn the engine off.

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

6. Block the rear wheels on the downhill side.

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OPERATION

HAULING CARGO WARNING

Hauling 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: 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. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions. Always operate the vehicle with extreme care when hauling or towing loads. Slow down and drive in the lowest gear available. Always use LOW gear when

towing or hauling heavy loads. 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 SAFELYARRANGED 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 a rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 16 km/h (10 MPH) while towing a load on a level grass surface. Vehicle speed should never exceed 8 km/h (5 MPH) when towing

loads in rough terrain, while cornering, or while ascending or descending a hill.

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OPERATION

LOAD CAPACITY Your 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.

WARNING Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride

in the cab with seat belts fastened securely.

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OPERATION

TOWING LOADS WARNING

Towing improperly can alter vehicle handling and may cause loss of control or brake instability.

Always follow these precautions when towing:

1. Never load more than 250 lbs. (113.4 kg) tongue weight on the towing bracket.

2. When towing a disabled vehicle, place the disabled vehicles transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

3. Towing a trailer increases braking distance. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

4. Do not tow more than the recommended weight for the vehicle.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location, which could result in loss of control of the vehicle.

6. The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

MODEL

TOTAL TOWED LOAD WEIGHT (LEVEL

GROUND)

TOTAL TOWED LOAD

WEIGHT (15 GRADE)

TOTAL HITCH VERTICAL WEIGHT

MAXIMUM TOWING SPEED

Polaris PRO XD

2500 lbs. (1134 kg)

850 lbs. (386 kg)

250 lbs (113.4 kg)

10 MPH (16 km/h)

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OPERATION

DUMPING THE CARGO BOX To dump the cargo box, do the following:

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes. Place the transmission in PARK.

3. Engage the park brake.

4. Ensure that the cargo is positioned evenly or toward the front of the cargo box.

5. Release the tailgate by pulling up on the tailgate latch.

WARNING If the weight distribution on the box is located toward the rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the Release Lever dump lever without ensuring that the load is positioned evenly or at the front of

the box.

6. Stand clear and pull up on the cargo box release leverq. Lift the front of the cargo box to dump the cargo.

7. Lower the cargo box and push down securely to latch.

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

cargo box in the raised position.

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OPERATION

82

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

WARNING Improper winch use can result in SEVERE INJURYor 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 91.

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.

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.

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WINCH GUIDE

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.Never immerse or submerse your winch in water. Your dealer can provide service on your winch if this occurs.

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

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

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

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

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WINCH GUIDE

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

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

need to use it in the field.

WARNING Improper winch use can result in SEVERE INJURYor 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.

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 91.

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

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WINCH GUIDE

WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURYor 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.

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.

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WINCH GUIDE

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

a. Release the winch clutch and spool out the necessary length of winch cable.

b. Align the winch cable as close as possible to the winching vehicles centerline.

c. Attach the winch cable hook to the anchor point or the stuck vehicles frame following instructions in this manual.

d. Re-engage the clutch on the winch.

e. Slowly winch in the slack in the winch cable.

f. Select the proper vehicle gear to propel the stuck vehicle in the direction of winching.

g. Shift to the lowest gear available on the stuck vehicle.

h. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.

i. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch.

j. Detach the winch cable hook.

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

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

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WINCH GUIDE

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 INJURYor DEATH to you and other bystanders.

Winch cables are designed to NOTabsorb 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 INJURYor 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 INJURYor 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 NOTalike. 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 INJURYor 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/.

EXHAUST EMISSION CONTROL SYSTEM Exhaust emissions are controlled by engine design. A fuel injection system controls fuel delivery. The engine and fuel injection components are set at the factory for optimal performance and are not adjustable. Your engine is designed to operate on ultra low sulfur diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with emissions requirements.

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

94

MAINTENANCE PERIODIC MAINTENANCE CHART Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, genuine POLARIS parts are available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log at the end of the manual.

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

dealer perform these operations.

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

SEVERE USE DEFINITION Frequent immersion in mud, water or sand Prolonged low speed, heavy load operation

MAINTENANCE INTERVALS The maintenance interval charts outline required maintenance and inspection based on vehicle hours / miles. Each table states the number of hours / miles that service is required on the vehicle. Some items or components may need to be serviced more often due to severe use, such as operation in water or under severe loads. When the vehicle goes beyond 500 hours / 5000 miles, return to the 50 hours / 500 mile chart and start the interval process over.

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

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

E - Emission Control System Service (California)

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MAINTENANCE

50 HOUR / 500 MILE (800 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines and fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

XU / E

Engine Oil & Filter Change

Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

XU Front / Rear Suspension Lubricate (if applicable)

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

96

MAINTENANCE

ITEM REMARKS

D Drive Belt Inspect; replace as needed

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

97

MAINTENANCE

100 HOUR / 1000 MILE (1600 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines / fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

D Fan/Alternator Belt Check fan belt tension and damage

XU Front / Rear Suspension Lubricate (if applicable)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

XU Transmission Lubricant (AGL) Change lubricant

D / E Fuel System Check for leaks at fill cap and fuel pump.

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

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MAINTENANCE

ITEM REMARKS

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test system

XU Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Front Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed

XU Shocks Visually inspect shock seals; change oil and seals if leaking

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MAINTENANCE

150 HOUR / 1500 MILE (2400 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines and fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

XU Front / Rear Suspension Lubricate (if applicable)

E Fuel Filter / Water Separator Replace filter

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

100

MAINTENANCE

200 HOUR / 2000 MILE (3200 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines / fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

D Fan/Alternator Belt Check fan belt tension and damage

XU Front / Rear Suspension Lubricate (if applicable)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

XU Transmission Lubricant (AGL) Change lubricant

D / E Fuel System Check for leaks at fill cap and fuel pump.

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

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MAINTENANCE

ITEM REMARKS

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test system

XU Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Front Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed

XU Shocks Visually inspect shock seals; change oil and seals if leaking

D Brake Fluid Change every two years (DOT 4)

102

MAINTENANCE

250 HOUR / 2500 MILE (4000 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines and fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

XU / E

Engine Oil & Filter Change

Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

Suspension Bushings Inspect at 250 hours; replace if necessary

XU Front / Rear Suspension Lubricate (if applicable)

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

103

MAINTENANCE

ITEM REMARKS

D Drive Belt Inspect; replace as needed

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

104

MAINTENANCE

300 HOUR / 3000 MILE (4800 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines / fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

D Fan/Alternator Belt Check fan belt tension and damage

XU Front / Rear Suspension Lubricate (if applicable)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

XU Transmission Lubricant (AGL) Change lubricant

D / E Fuel System Check for leaks at fill cap and fuel pump.

E Fuel Filter / Water Separator Replace filter

105

MAINTENANCE

ITEM REMARKS

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test system

XU Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Front Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed

XU Shocks Visually inspect shock seals; change oil and seals if leaking

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MAINTENANCE

350 HOUR / 3500 MILE (5600 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines and fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

XU Front / Rear Suspension Lubricate (if applicable)

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

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MAINTENANCE

400 HOUR / 4000 MILE (6400 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines / fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

D Fan/Alternator Belt Check fan belt tension and damage

XU Front / Rear Suspension Lubricate (if applicable)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

XU Transmission Lubricant (AGL) Change lubricant

D / E Fuel System Check for leaks at fill cap and fuel pump.

E Fuel Filter / Water Separator Replace filter

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MAINTENANCE

ITEM REMARKS

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test system

XU Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Front Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed

XU Shocks Visually inspect shock seals; change oil and seals if leaking

D Brake Fluid Change every two years (DOT 4)

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MAINTENANCE

450 HOUR / 4500 MILE (7200 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines and fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

XU / E

Engine Oil & Filter Change

Perform a break-in oil and filter change at 50 hours or one month; perform every 200 hours or 6 months thereafter

XU Front Gearcase Lubricant Inspect / add lubricant if needed

XU Transmission Lubricant (AGL) Inspect / add lubricant if needed

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

XU Front / Rear Suspension Lubricate (if applicable)

E Fuel Filter / Water Separator Replace filter

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

110

MAINTENANCE

500 HOUR / 5000 MILE (8000 KM) SERVICE ITEM REMARKS

XU / D

Brake Pads / Parking Brake Pads

Inspect pad wear; replace if worn beyond service limit

D / E Fuel System Turn key on to pressurize fuel pump; check

lines / fittings for leaks and abrasion

XU / D

Parking Brake Cable Adjustment Inspect; adjust tension as needed

Battery Check terminals; clean; test

D / E Throttle Pedal Inspect; replace if it sticks

XU Air Filter / Air Box Inspect/clean; replace filter as needed, or yearly

E Air Intake Ducts/ Adapters

Inspect ducts for proper sealing / air leaks

Shift Cable / Linkage Inspect; adjust as needed

D Steering Inspect for loose components and torn boots; replace parts as needed

Suspension Bushings Inspect at 250 hours; replace if necessary

D Fan/Alternator Belt Replace belt

XU Front / Rear Suspension Lubricate (if applicable)

D Cooling System Inspect coolant strength seasonally; pressure test system yearly

D Drive Belt Inspect; replace as needed

XU Front Gearcase Lubricant Change lubricant

XU Transmission Lubricant (AGL) Change lubricant

D / E Fuel System Check for leaks at fill cap and fuel pump.

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MAINTENANCE

ITEM REMARKS

E Fuel Filter / Water Separator

Drain every 50 hrs (normal conditions with quality fuel) or daily (severe conditions with poor fuel quality)

XU Radiator Inspect; clean external surfaces

XU Cooling Hoses Inspect for leaks; pressure test system

XU Engine Mounts Inspect, torque to specification

Exhaust Silencer / Pipe Inspect

XU Wiring Inspect for wear, routing, security; inspect connectors subjected to water, mud, etc.

D Clutches (Drive and Driven) Inspect; clean; replace worn parts

D Front Wheel Bearings Inspect; replace as needed

Tires / Wheels Inspect tire tread at 100 hrs; rotate as needed

XU Shocks Visually inspect shock seals; change oil and seals if leaking

D Brake Fluid Change every two years (DOT 4)

XU Coolant Replace coolant

D Toe Adjustment Inspect periodically; adjust when parts are replaced

When the vehicle goes beyond 500 hours / 5000 miles, return to the 50 hours / 500 mile chart and start the interval process over.

EXTENDED ITEMS REMARKS

Engine Check valve clearance every 800 hours

Engine Check injection nozzle condition every 1000 hours

Engine Check injection timing every 3000 hours

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MAINTENANCE

LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart, 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. ITEM LUBE METHOD

Engine Oil Full Synthetic POLARIS Diesel Oil (SAE 5W-40)

Add to proper level on dipstick. See page 113.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 142.

Transmission Oil (Main Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

See page 120.

Demand Drive Fluid (Front Gearcase)

Demand Drive Fluid See page 121.

Prop Shaft U-Joint Grease Locate fittings and grease.

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.

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.

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MAINTENANCE

OIL RECOMMENDATIONS POLARIS recommends the use of full synthetic POLARIS Diesel Oil (SAE 5W- 40) for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation. See the chart below.

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

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

OIL VISCOSITY / AMBIENT AIR TEMPERATURE CHART SAE 5W-40

SAE 15W-40

-31 C (-25 F)

-15 C (+5 F)

+27 C (+80 F)

+40 C (+104 F)

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MAINTENANCE

OIL CHECK This engine has a wet-sump design, meaning the engine oil is contained in the bottom of the crankcase. To check the oil level, follow the procedure listed below:

1. Check the oil when the engine is cold and safe to touch.

2. Make sure that the vehicle is on a level surface and that the transmission in PARK.

3. Locate the dipstickq on the right side of the unit.

4. Remove the dipstick and wipe it dry with a clean cloth.

5. Reinstall the dipstick and push it into place.

NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to keep

the depth of the dipstick consistent.

6. Remove the dipstick and check the oil level.

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MAINTENANCE

7. Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

NOTICE A rising oil level between checks during cold weather operation can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil

level is over the upper mark, change the oil immediately.

8. With the cargo box raised, add engine oil through the oil fill capw located on top of the valve cover, under the cargo box.

9. When finished, reinstall dipstick. Lower the cargo box and secure in position.

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MAINTENANCE

OIL AND FILTER CHANGE Always change engine oil and filter at the intervals outlined in the Periodic Maintenance Chart. Always change the oil filter whenever changing the engine oil. The engine oil dipstick is located on the right front side of the engine. The engine oil fill cap is located on top of the valve cover. Access the oil fill cap by tilting the rear cargo box.

The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the skid plate access hole located directly under the crankcase.

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

2. Stop the engine and allow it to cool down.

3. Clean the area around the crankcase drain plug.

CAUTION Use caution when performing this procedure. Do not allow hot engine oil to

come into contact with skin, as serious burns may result.

4. Place a drain pan under the engine crankcase and remove the drain plugq. Allow the oil to drain completely.

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MAINTENANCE

5. Using an oil filter wrench, turn the oil filterw counter-clockwise to remove it.

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

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

8. Install the new filter and turn by hand until the filter O-ring contacts the sealing surface, then turn an additional 3/4 turn

9. Replace the sealing washer on drain plug.

NOTICE The sealing surface on the drain plug should be clean and free of burrs, nicks

or scratches.

10.Reinstall the engine crankcase drain plug. Torque the drain plug to 12 ft-lbs (16 Nm).

11. Remove all cargo from the cargo box.

CAUTION Always remove all cargo from the cargo box before lifting the box to access the

engine.

12.Pull up on the cargo box release lever to tilt the box.

13.Remove oil fill cap and add 3.7 L (3.9 quarts) of recommended oil. Reinstall the fill cap.

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MAINTENANCE

14.Verify the transmission is still in PARK.

15.Start the engine and allow it to idle for 30 seconds.

16.Stop the engine and inspect for oil leaks. Wait at least 15 seconds before removing the dipstick.

17.Remove the dipstick and wipe it dry with a clean cloth.

18.Reinstall the dipstick and push it into place.

NOTICE Make certain the dipstick is inserted all the way into the dipstick tube to keep

the depth of the dipstick consistent.

19.Remove the dipstick and check the oil level.

20.Add the recommended oil as necessary to bring the oil level within the SAFE range on dipstick. Do not overfill.

NOTICE Add oil slowly, to make sure oil does not get into the breather or intake.

21.When finished, reinstall the oil fill cap and oil dipstick.

22.Dispose of used oil and filter properly.

119

MAINTENANCE

GEARCASES GEARCASE SPECIFICATION CHART

GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE

DRAIN PLUG/ LEVEL CHECK PLUG TORQUE

Transmission (Main Gearcase)

AGL Gearcase Lubricant & Transmission Fluid

41 oz. (1200 ml)

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

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

Demand Drive Unit (Front Gearcase)

Demand Drive Fluid

9.3 oz. (275 ml)

8-10 ft. lbs. (11-13.6 Nm)

11 ft. lbs. (15 Nm)

TRANSMISSION (MAIN GEARCASE) TRANSMISSION OIL CHECK Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

To check the transmission fluid, do the following:

1. Position the vehicle on a level surface.

2. Remove the fill plugq.

3. Check the fluid level.

4. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

5. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

TRANSMISSION OIL CHANGE The drain plug is located on the bottom of the gearcase. Access the drain plug through the hole in the skid plate.

1. Remove the fill plugq.

2. Place a drain pan under the drain plugw.

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

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

5. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

DEMAND DRIVE (FRONT GEARCASE) (IF EQUIPPED) DEMAND DRIVE OIL CHECK Always check and change the demand drive fluid 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. The front gearcase fill plugq is located on the right side of the front gearcase.

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to specification.

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MAINTENANCE

DEMAND DRIVE OIL CHANGE 1. Support the vehicle securely with a jackstand.

2. Remove the front tire on the passenger's side.

3. Remove the fill plug.

4. Place a drain pan under the drain plugw on the bottom right-hand side.

5. Remove the drain plug. Drain the oil.

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

7. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10.Discard used oil properly.

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MAINTENANCE

COOLING SYSTEM The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, 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. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.

ADDING OR CHANGING COOLANT POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. 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, the level in the radiator should be inspected. Add coolant as needed.

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.

NOTICE Washing the vehicle with a high-pressure hose could damage the radiator fins and impair the radiator's effectiveness. Using a high-pressure system is not

recommended.

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RADIATOR COOLANT LEVEL 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 consequentially, engine damage.

1. Lift the hood.

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.

2. Slowly remove the radiator capq.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

TIP This procedure is required only if the cooling system has been drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in

the radiator should also be inspected.

5. 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.

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OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the overflow bottleq.

3. If the coolant level is below the safe operating range, lift the hood and locate the overflow bottle lid. Remove the cap and use a funnel to add coolant through the filler opening. Reinstall the cap.

TIP If coolant must be added often, or if the overflow bottle runs completely dry,

there may be a leak in the system. Your dealer can inspect the cooling system.

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POLARIS VARIABLE TRANSMISSION (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 PVTsystem. 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 PVTsystem rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for

your own safety and the safety of others:

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

See your dealer or other qualified service person as outlined in the owner's manual.

This PVTsystem 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.

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BELT REMOVAL If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine compartments when replacing the belt.

WARNING Failure to remove ALL debris when replacing the belt could result in vehicle

damage, loss of control and severe injury or death.

NOTE Inspect the entire clutch outlet duct (including the outlet duct screen) when

replacing a drive belt. Remove any debris found in the outlet duct or outlet duct screen.

To remove the belt, do the following:

1. Remove the nine fastenersq that retain the outer clutch cover.

NOTE Removal of left rear wheel or left rear shock is NOT necessary for belt

replacement.

2. Pull the clutch cover forward and slide towards the front of the vehicle as shown above.

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3. Rotate the clutch cover back and lift up and over the control arm mounting w.

NOTE Use care when lifting clutch cover upwards. Do not damage cover, intake boot,

or electrical harness.

4. Pull clutch cover out towards the rear of the vehicle as shown above.

5. Mark the drive belt direction of rotation so that it can be installed in the same direction.

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6. Insert clutch spreader toole into threaded hole on driven clutch as shown and turn clockwise to spread clutch.

NOTE Clutch spreader tool part number 2875911 is found in vehicle tool kit.

7. Walk the belt out of the driven clutch and drive clutch. Remove the belt from the vehicle.

BELT INSPECTION To inspect the drive belt, do the following:

1. Inspect belt for hour-glassing (extreme circular wear in at least one spot and on both sides of the belt). Hour glassing occurs when the drive train does not move and the drive clutch engages the belt.

2. Inspect belt for loose cords, missing cogs, cracks, abrasions, thin spots, or excessive wear. Compare belt measurements with a new drive belt. Replace if necessary.

3. Belts with thin spots, burn marks, etc., should be replaced to eliminate noise, vibration, or erratic PVToperation.

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BELT INSTALLATION NOTE

Be sure to install belt in the same direction as it was removed.

1. With the clutch spreader toolq installed, loop the belt over the drive clutch and over the driven clutch.

2. Rotate the driven clutch and walk the belt into the clutch.

3. Remove the clutch spreader tool from driven clutch.

4. Rotate / spin the driven clutch and belt approximately 5-7 times to properly seat the belt in the driven clutch.

5. Install the clutch cover into wheel well as shown above.

6. Rotate clutch cover over A-Armw as shown below. Use care not to damage intake boots or electrical harness.

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7. Pull clutch cover backwards and align with bolt holes on inner clutch cover as shown below.

8. Install and torque the outer clutch cover bolts to specification.

TORQUE PVT Outer Cover Fasteners

35 in-lbs (4 Nm)

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POLARIS VARIABLE TRANSMISSION (PVT) DRYING There may be some instances when water is ingested into the PVTsystem. Use the following instructions to dry it out before operating:

1. Position the vehicle on a level surface.

2. Remove the red drain plug on the outer clutch cover. Allow the water to drain completely. Reinstall the drain plug.

3. Place the transmission in PARK.

4. Start the engine.

5. 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 five (5) seconds.

6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range.

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

8. Your vehicle requires service as soon as possible. Your POLARIS dealer can assist.

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VEHICLE IMMERSION WARNING

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 vehicle to a dealer before starting it, follow the steps outlined below:

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

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Remove the spark plugs. Turn the engine over several times using the electric start.

4. Dry the spark plugs and reinstall, or replace with new plugs.

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

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

7. If water has been ingested into the PVT follow the procedure for drying.

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AIR FILTER REPLACEMENT Inspect the air filter at the intervals outlined in the Periodic Maintenance Chart. In extremely dusty conditions, air filter replacement will be required more often.

1. Locate the air filter on the left side of the unit.

2. Release the two airboxw cover latches.

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3. Remove the covere to access the air filter elementr.

4. Inspect the airbox for oil or water deposits. Wipe away any deposits with a clean shop towel.

IMPORTANT If the filter has been soaked with fuel or oil it must be replaced.

DO NOTattempt to clean the air filter.

5. Place the air filter into the airbox. Reposition the airbox cover and install the two retaining latches.

NOTICE Make sure the hinge pins are properly seated when reassembling the airbox

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ALTERNATOR BELT Belt Adjustment Check the alternator belt at the correct service interval as outlined in the Periodic Maintenance Chart.

Stop the machine on a flat level surface. Put the gear selector in Park, stop the engine and exit the vehicle. See the Stopping the Engine section.

1. Raise the cargo box.

2. The belt tension is correct with 0.3 in. (7.6 mm) of belt deflection at the mid span at the top of the beltq, when 20 lbf (89 N) is applied to the belt.

3. If the belt tension is not correct, loosen the mounting boltw and adjustment bolte.

4. Move the top of the alternatorr to tighten the belt.

5. Tighten the mounting bolt to 17.3-20.3 ft-lbs .(23.5-27.5 Nm).

6. Tighten the adjustment bolt to 17.3-20.3 ft-lbs. (23.5-27.5 Nm).

7. Lower the cargo box.

FUEL FILTER / WATER SEPARATOR The fuel filter/water separator is located under the seat on the left side of the vehicle, between the engine and fuel tank. Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart. Service the separator more frequently if the vehicle is operated with inferior fuel.

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CAUTION Both fuel and water will drain from the separator during the following

procedure. Use caution and observe all fuel safety precautions when handling fuel.

1. Remove the seat. Disconnect the battery.

2. Place an appropriate container under the fuel filter drain to catch fluids (water and fuel).

3. Slightly loosen the bleed screw to relieve fuel pressure in the filter. Do not tighten the screw at this time.

4. Reach under the fuel filter and slightly loosen the drain valveq until the fluids drain from the drain hole. Do not completely unscrew the drain valve.

5. When fluids stop draining from the valve, tighten the valve firmly (by hand only).

6. Reconnect the battery.

7. Turn the ignition key on to engage the fuel pump. Leave the key on only until fuel begins to spit from the bleed screww, then tighten the screw.

8. Clean up any spilled fuel and soiled shop towels properly.

9. Cycle the key switch from OFF to ON six times, waiting three seconds at each ON cycle to allow the fuel pump to cycle.

10.Start the engine and check for fuel leaks.

11. Reinstall the seat.

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THROTTLE SYSTEM WARNING

Failure to check or maintain proper operation of the throttle system can result in an accident and lead to serious injury or death if the throttle pedal sticks

during operation. Always check the pedal for free movement and return before starting the

engine and occasionally during operation. Never start or operate this vehicle if it has a sticking or improperly operating throttle pedal. Immediately contact

your dealer for service if throttle problems arise.

THROTTLE FREEPLAY If the throttle pedal has excessive play due to cable stretch or maladjustment, it will cause a delay in throttle response, especially at low engine speed. The throttle may also not open fully. If the throttle pedal has no freeplay, the throttle may be hard to control, and the idle speed may be erratic. Check the throttle pedal freeplay at the intervals outlined in the Periodic Maintenance Chart. Adjust the freeplay if necessary.

THROTTLE FREEPLAY INSPECTION 1. Apply the brakes. Engage the park brake. Shift the transmission to neutral.

2. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 of an inch to 1/8 of an inch (1.6-3.2 mm).

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

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THROTTLE CABLE ADJUSTMENT CABLE ADJUSTMENT 1. Ensure that the throttle cable is properly routed and retained to the unit.

2. On the pedal side, tighten jam nutsq.

TORQUE Throttle Cable Jam Nut (pedal side)

43 in-lbs (5 Nm)

3. On the engine side, tighten jam nutsw.

TORQUE Throttle Cable Jam Nut (engine side)

10 ftlbs (13 Nm)

4. Slide back the protective cover to expose the jam nute and adjuster screwr.

5. Loosen the jam nut and turn the adjuster screw until the throttle lever on the engine moves.

6. Loosen the adjuster back so there is no tension in the cable.

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7. Once properly adjusted, tighten the jam nut against the adjuster and re-install the protective sleeve.

8. Start the engine and allow if to warm up thoroughly. Measure the distance the throttle pedal moves before the engine begins to pick up speed. Freeplay should be 1/16 of an inch to 1/8 of an inch (1.6-3.2 mm).

THROTTLE PEDAL ADJUSTMENT NOTICE

It is ideal to adjust the throttle pedal with the help of an assistant.

1. Loosen the adjustment screwq and jam nutw.

2. With the vehicle off and in park, have the assistant fully depress and hold down the throttle pedal.

3. The person on the engine side should manually press the lever on the engine to ensure that full travel is being achieved.

4. Release the pedal and engine lever and adjust the pedal adjustment screw out 1/2 turn at a time and continue this process until full travel of the engine lever is NOTobtained.

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5. Slowly adjust the pedal adjuster in a 1/4 turn at a tie until the full engine throttle IS obtained. Once proper adjustment is obtained, tighten jam nut in place to hold the adjustment position.

TORQUE Throttle Pedal Adjuster Jam Nut

14 ftlbs (19 Nm)

6. With the unit in park, start the unit. Ensure the engine idle is still within range of 1200 +/- 100 RPM. Fully depress the throttle pedal and ensure that the engine RPM gets to 3850 +/- 50 RPM.

CAUTION DO NOT HOLD hold the unit wide open for more than 10 seconds.

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BRAKES The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to engage the brakes.

BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.

WARNING After opening a bottle of brake fluid, always discard any unused portion. Never

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

accident or severe injury.

Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown.

1. Position the vehicle on a level surface and turn off the engine.

2. View the brake fluid level at the reservoir in the drivers side wheel well. The level should be between the upper (MAX) and lower (MIN) level lines.

3. If the fluid level is lower than the upper level line, open the hood and add brake fluid to the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid leakage around the fittings.

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BRAKE INSPECTION WARNING

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

pad and caliper.

1. Check the brake system for fluid leaks.

2. Check the brake pedal for excessive travel or a spongy feel.

3. Check the friction pads for wear, damage and looseness.

4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol.

5. Inspect the brake disc spline and pad wear surfaceq for excessive wear. Change pads when worn to 0.030" (0.762 mm).

STEERING WHEEL INSPECTION Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart section.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8"-1.0" (20-25 mm) of freeplay.

4. If there is excessive freeplay or strange noises, or the steering feels rough or catchy, have the steering system inspected by an authorized dealer.

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SPRING ADJUSTMENT (IF APPLICABLE) Adjust the front and rear shock absorber springs by rotating the adjustment cam q either clockwise or counterclockwise to increase or decrease spring tension.

TIRES WARNING

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

approved size and type of tires for this vehicle when replacing tires.

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

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TIRE ROTATION Tire rotation is recommended for every 500-mile (805-km) interval. Perform tire rotation on the vehicle by following the rearward cross strategy shown below.

AXLE AND WHEEL NUT TORQUE SPECIFICATIONS Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut.

Lug Nut (Aluminum Wheels)

Front and Rear 120 ft-lbs (163 Nm)

2-Piece Flange Nut (Steel Wheels) Front and Rear 60 ft-lbs (81 Nm)

Spindle Nut Front 110 ft. lbs. (149 Nm)

Hub Retaining Nut Rear 180 ft. lbs. (244 Nm)

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WHEEL REMOVAL 1. Position the vehicle on a level surface.

2. Place the transmission in PARK. Stop the engine.

3. Loosen the wheel nuts slightly.

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

5. Remove the wheel nuts and washers. Remove the wheel.

WHEEL INSTALLATION 1. Place the transmission in PARK.

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

WARNING Improperly installed wheels can adversely affect tire wear and vehicle

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

installed. Your dealer can assist.

3. Attach the wheel nuts and washers and finger-tighten.

4. Carefully lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

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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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. When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

HEADLIGHT BULB REPLACEMENT 1. Remove the hood from the front cab.

2. Locate the bulb on the back side of the headlight housing.

3. Disconnect the harness from the bulb. Be sure to pull on the connector, not on the wiring.

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4. Turn the bulb counterclockwise and remove it from the headlight housing.

5. Install the new bulb into the housing and rotate it clockwise 90 to lock it in place.

NOTICE Make sure the tab on the bulb locates properly in the housing.

6. Install the harness onto the new headlight bulb and install the hood.

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HEADLIGHT BEAM ADJUSTMENT

To adjust the headlight beam, do the following:

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

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. Apply the brakes. Start the engine. Turn on the headlights.

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

5. If a headlight needs adjustment, locate the adjustment screw at the back of the headlight.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

BRAKE LIGHTS When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. To check the brake lights, do the following:

1. Turn the key to the ON position.

2. Depress the brake pedal. The brake light should come on after about 10mm (0.4 in.) of pedal travel. If the light doesn't come on, check the bulb.

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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. The fuse box is located under the seat, next to the batteryq. Spare fuses are provided in the fuse box. If you suspect that a fuse or relay may not be working properly, your dealer can assist.

FUSE SIZE FEATURE SUPPORTED

40A Glow Plugs

30A Starter Solenoid

30A EPS

20A Chassis

20A Accessories

15A Lights

15A EFI (Engine Controller)

10A Battery Charging Port

10A Horn

10A Brake Lights

10A Fuel Pump

10A Alternator

10A Drive Mode

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BATTERY Your vehicle has a sealed battery, which requires little maintenance. 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.

BATTERY REMOVAL 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.

1. Remove the storage bin under the passenger seat to access the battery.

2. Disconnect the black (-) battery cable first. Disconnect the red (+) battery cable last.

3. Remove the battery hold-down strap.

4. Lift the battery out of the vehicle.

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

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder. Make sure the positive terminal is toward the drivers side of the vehicle.

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

4. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.

5. Install the hold-down strap.

6. Reinstall the storage bin and seat.

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

TIP Battery charge can be maintained 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 predetermined 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.

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

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

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher.

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

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

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

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STATE OF CHARGE VOLTAGE ACTION CHARGE TIME*

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

None required

75%-100% 12.5-12.8 volts

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

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours

25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge

0%-25% 11.5 volts or less Needs charge with desulfating charger

At least 20 hours

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

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CLEANING AND STORAGE WASHING THE VEHICLE Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components.

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

NOTE Certain products, including insect repellents and chemicals, will damage

plastic surfaces. Do not allow these types of products to contact the vehicle.

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

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

2. Rinse with clean water frequently.

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

WASHING TIPS Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish.

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.

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

Wheel bearings Radiator Transmission seals Brakes

Cab and body panels Labels and decals Electrical components and wiring Air intake components

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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.

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.

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.

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)

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INSPECT AND LUBRICATE Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart.

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.

REMOVAL FROM STORAGE 1. Charge the battery if necessary. Install it in the vehicle.

2. Fill the fuel tank with fuel.

3. Check all the points listed in the Daily Pre-Ride Inspection section. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer.

4. Lubricate at the intervals outlined in the Periodic Maintenance Chart.

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TRANSPORTING THE PRO XD Follow these procedures when transporting the vehicle.

1. Place the transmission in PARK.

2. Stop the engine.

3. Engage the park brake.

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

5. Secure the fuel cap, hood and cargo box. Ensure that the seats are attached correctly and are not loose.

WARNING Cargo and other loose vehicle parts may fly off while transporting this vehicle.

Secure or remove all cargo, and inspect the unit for loose parts prior to transport.

If transporting the vehicle in a non-enclosed trailer, then the vehicle must FACE FORWARD, or roof must be removed.

Failure to comply may allow airflow, vibration, or other factors to separate the roof from the vehicle and cause an accident, resulting in serious personal

injury or death.

6. Always tie the frame of the PRO XD to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets. Always secure the vehicle to the trailer using the designated tie down points (frontq and rearw).

7. Remove the key to prevent loss during transporting.

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TOWING A PRO XD Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. 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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SPECIFICATIONS 2000D

POLARIS PRO XD 2000D

Maximum Weight Capacity

2000D AWD: 1900 lbs. (862 kg) (including operator, passenger, cargo, accessories) 2000D 4x2: 1900 lbs. (862 kg) (including operator, passenger, cargo, accessories)

Dry Weight 2000D AWD: 1665 lbs. (755 kg) 2000D 4x2: 1665 lbs. (755 kg)

GVWR Gross Vehicle Weight Rating

2000D AWD: 3600 lbs. (1633 kg) per ANSI/OPEI B71.9-2016, Section 5.1.2 2000D 4x2: 3600 lbs. (1633 kg) per ANSI/OPEI B71.9-2016, Section 5.1.2

Fuel Capacity 11.5 gallons (43.5 liters)

Engine Oil Capacity 3.7 liters (3.9 quarts)

Coolant Capacity 5.5 liters (5.8 quarts)

Towing Capacity 2500 lbs. (1134 kg)

Hitch Tongue Capacity

250 lbs. (113 kg)

Max. Cargo Box Load 1250 lbs. (567 kg)

Overall Length 126 in. (320 cm)

Overall Width 62.5 in. (158.8 cm)

Overall Height 75 in. (191 cm)

Wheelbase 85 in. (215.9 cm)

Cargo Box Dimensions (Inside)

54 inches wide, 43.5 inches long, 11.5 inches high (137 cm wide, 110 cm long, 29 cm high)

Ground Clearance 11 in. (27.9 cm)

Min. Turning Radius 112 in. (284.5 cm)

Engine Kubota liquid-cooled 3 cylinder diesel

Displacement 898 cc

159

SPECIFICATIONS

POLARIS PRO XD 2000D

Bore x Stroke 72 mm x 73.6mm

Alternator Output 12V DC 140A

Compression Ratio 22.8:1

Starting System Electric

Fuel System Mechanical fuel injection

Front Suspension Dual A-arm w/ 9 in. (22.86 cm) of travel

Rear Suspension Independent w/ 9 in. (22.86 cm) of travel

Lubrication System Full pressure with full flow filter

Driving System Type PVT, 4-wheel independent shaft, lockable differential

Shift Type Single Lever (H/L/N/R/P)

Transmission Gear Ratio - High

Front 5.17:1 / Rear 15.45:1

Transmission Gear Ratio - Low

Front 9.65:1/ Rear 28.84:1

Transmission Gear Ratio - Reverse

Front 9.16:1 / Rear 27.39:1

Front Drive Ratio 3.82:1

Tire Size - Front 26 x 10 - 12

Tire Size - Rear 26 x 10 - 12

Tire Pressure - Front 24 psi (165 kPa)

Tire Pressure - Rear 24 psi (165 kPa)

Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

Hood Headlight 2 single beam, 50W, quartz/halogen

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

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SPECIFICATIONS

4000D POLARIS PRO XD 4000D

Maximum Weight Capacity

2075 lbs. (941 kg) (including operator, passengers, cargo, accessories)

Dry Weight 1925 lbs. (873 kg)

GVWR Gross Vehicle Weight Rating

4000 lbs. (1814 kg) per ANSI/OPEI B71.9-2016, Section 5.1.2

Fuel Capacity 11.5 gal. (43.5 liters)

Engine Oil Capacity 3.7 liters

Coolant Capacity 6.25 liters

Towing Capacity 2500 lbs. (1134 kg)

Hitch Tongue Capacity

250 lbs. (113 kg)

Max. Cargo Box Load 1250 lbs. (567 kg)

Overall Length 157 in. (399 cm)

Overall Width 62.5 in. (158.8 cm)

Overall Height 75 in. (191 cm)

Wheelbase 117 in. (297 cm)

Cargo Box Dimensions (Inside)

54 inches wide, 43.5 inches long, 11.5 inches high (137 cm wide, 110 cm long, 29 cm high)

Ground Clearance 11 in. (27.9 cm)

Min. Turning Radius 154 in. (391.2 cm)

Engine Kubota liquid-cooled 3 cylinder diesel

Displacement 898 cc

Bore x Stroke 72 mm x 73.6mm

Alternator Output 12V DC 140A

Compression Ratio 22.8:1

161

SPECIFICATIONS

POLARIS PRO XD 4000D

Starting System Electric

Fuel System Mechanical fuel injection

Front Suspension Dual A-arm w/9 in. (25.4 cm) of travel

Rear Suspension Independent w/9 in. (25.4 cm) of travel

Lubrication System Full pressure with full flow filter

Driving System Type PVT, 4-wheel independent shaft, lockable differential

Shift Type Single Lever (H/L/N/R/P)

Transmission Gear Ratio - High

Front 5.17:1 / Rear 15.45:1

Transmission Gear Ratio - Low

Front 9.65:1/ Rear 28.84:1

Transmission Gear Ratio - Reverse

Front 9.16:1 / Rear 27.39:1

Front Drive Ratio 3.23:1

Tire Size - Front 26 x 10 - 12

Tire Size - Rear 26 x 10 - 12

Tire Pressure - Front 24 psi (165 kPa)

Tire Pressure - Rear 24 psi (165 kPa)

Brakes, Front/Rear Foot Activated, 4 wheel hydraulic disc

Hood Headlight 2 single beam, 50W, quartz/halogen

Taillights 10 L.E.D. (.28W)

Brake Light 10 L.E.D. (3.1W)

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SPECIFICATIONS

POLARIS PRODUCTS PART NUMBER DESCRIPTION

Engine Lubricant

2878473 15W-40 Diesel Oil (1.9 l/2 qt.)

2879832 5W-40 Synthetic Diesel Oil (1.9 l/2 qt.)

Gearcase / Transmission Lubricants

2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (.95 l/1 qt.)

2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (3.8 l/1 gal.)

2877922 Demand Drive Fluid (.95 l/1 qt.)

2877923 Demand Drive Fluid (3.8 l/1 gal.)

2870465 Pump for 3.8 l/1 gal. Jug

Coolant

2880514 Antifreeze 50/50 Premix (.95 l/1 qt.)

2880513 Antifreeze 50/50 Premix (3.8 l/1 gal.)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, All Season Grease

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

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

2876160 ATVAngle Drive Fluid (.95 l/1 qt.)

2872276 ATVAngle Drive Fluid (9.5 l/2.5 gal.)

2871460 Premium Starter Grease

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

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

2871329 Dielectric Grease (Nyogel)

Additives / Miscellaneous

2872189 DOT 4 Brake Fluid

2871956 Loctite 565 Thread Sealant

2859044 POLARIS Battery Tender Charger

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POLARIS PRODUCTS

164

TROUBLESHOOTING DRIVE BELT WEAR/SPIN

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 clogged air filter, clogged fuel filter, water in the fuel or foreign material in fuel 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.

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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 electronic control box connections

Inspect, clean, reinstall connectors

ENGINE TURNS OVER, FAILS TO START POSSIBLE CAUSE SOLUTION

Out of fuel Refuel

Clogged fuel filter/water separator

Replace

Clogged air filter Replace

Water is present in fuel Drain the fuel system and refuel, replace fuel filter/ water separator

Old or non-recommended fuel Replace with fresh recommended fuel

Water or fuel in crankcase Immediately see your POLARIS dealer

Low battery voltage Recharge the battery to 12.8 VDC

Mechanical failure See your dealer

Defective glow plug Inspect and replace

Defective stop solenoid Replace

Defective fuel pump Replace

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TROUBLESHOOTING

ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION

Old or non-recommended fuel Replace with fresh recommended fuel

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with fresh recommended fuel

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

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TROUBLESHOOTING

ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION

Poor fuel quality or incorrect fuel

Replace with recommended fuel

Low fuel level Refuel

Clogged fuel filter Replace

Clogged air filter Replace

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with new fuel

Kinked or plugged fuel tank vent line

Inspect and replace

Other mechanical failure Your dealer can assist

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TROUBLESHOOTING

ENGINE STOPS OR LOSES POWER POSSIBLE CAUSE SOLUTION

Poor fuel quality or incorrect fuel

Replace with recommended fuel

Clogged fuel filter Replace

Clogged air filter Replace

Loose ignition connections Check all connections and tighten

Water present in fuel Replace with new fuel

Kinked or plugged fuel tank vent line

Inspect and replace

Other mechanical failure See your dealer

Out of fuel Refuel

Low battery voltage Recharge the battery to 12.8 VDC

Overheated engine Clean radiator screen and core, clean engine exterior, operate at lower load, see your dealer

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TROUBLESHOOTING

170

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

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

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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

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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 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.

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 ONE YEARWARRANTY 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 NOTAPPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.

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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 vehicle.

IF YOU PURCHASE FROM A PRIVATE PARTY: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.

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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.

NOTICE If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

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KUBOTA CORPORATION FEDERAL & CALIFORNIA EMISSION CONTROL SYSTEMS LIMITED WAR- RANTY FOR NON-ROAD ENGINES (CI) The U.S. Environmental Protection Agency (EPA), the California Air Resources Board (CARB), and KUBOTA Corporation (KUBOTA) are pleased to explain the Federal and California Emission Control System Warranty on your non-road engine or marine engine. In California, new 2019 model year heavy duty off-road engines must be designed, built and equipped to meet Californias stringent anti- smog standards adopted by the Air Resources Board pursuant to its authority in Chapter 1 and 2, Part 5, Division 26 of the California Health and Safety Code. In other states of the U.S.A., new non-road engines subject to the provisions of 40 CFR 1039 subpart A and new marine engines subject to the provisions of 40 CFR 1042 subpart A must be designed, built and equipped, at the time of sale, to meet the U.S. EPA regulations. KUBOTA must warrant the emission control system on your Compression Ignition engine for the period of time listed below provided there has been no abuse, vandalism, neglect, improper maintenance or unapproved modifications to your engine. This emission warranty is applicable in all states of the U.S.A., its provinces and territories regardless of whether an individual state, province, or territory has enacted warranty provisions that differ from the Federal warranty provisions. This emission warranty is also applicable in all provinces and territories of CANADA.

Your emission control system may include parts such as the fuel injection system and the air induction system. Also included may be hoses, belts, connectors and other emission-related assemblies.

Where a warrantable condition exists, KUBOTA will repair your engine at no cost to you, including diagnosis (if the diagnostic work is performed at an authorized dealer), parts and labor.

EMISSION DESIGN AND DEFECT WARRANTY COVERAGE The emissions warranty period for the engine begins on the original date of sale to the initial purchaser and continues for each subsequent purchaser for the period mentioned below.

If any emission related part on your engine is defective, the part will be repaired or replaced by KUBOTA free of charge.

1. For non-road engines

The emissions warranty period for all engines rated under 19kW (25 Hp) is 2000 hours of operation or two (2) years of use, whichever first occurs.

The emissions warranty period for constant speed engines rated under 37kW (50Hp) with rated speeds greater than or equal to 3000 rpm is 2000 hours of operation or two (2) years of use, whichever first occurs.

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The emissions warranty period for all other engine not already listed is 3000 hours of operation or five (5) years of use, whichever first occurs.

2. For marine engines (commercial Category 1)

The emissions warranty period for all engines rated under 19kW (25 Hp) is 1500 hours of operation or two and a half (2.5) years of use, whichever first occurs.

The emissions warranty period for all engines rated at or above 19 kW (25 Hp) and under 37kW (50 Hp) is 2500 hours of operation or three and a half (3.5) years of use, whichever first occurs.

The emissions warranty period for all engines rated at or above 37kW (50 Hp) is 5000 hours of operation or five (5) years of use, whichever first occurs.

OWNERS WARRANTY RESPONSIBILITIES (a) As the engine owner, you are responsible for the performance of the required maintenance listed in your KUBOTA operators manual. KUBOTA recommends that you retain all receipts covering maintenance on your engine, but KUBOTA cannot deny a warranty claim solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

(b) As the engine owner, you should be aware, however, that KUBOTA may deny your warranty coverage if your engine or a part has failed due to abuse, vandalism, neglect, improper maintenance or unapproved modifications.

(c) Your engine is designed to operate on Ultra Low Sulfur Diesel Fuel only. Use of any other fuel may result in your engine no longer operating in compliance with Federal or Californias emissions requirements.

(d) You are responsible for presenting your engine to the nearest dealer or service station authorized by KUBOTA when a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

(e) If you have any questions regarding your warranty rights and responsibilities or the location of the nearest authorized dealer or distributor, you should contact:

KUBOTA ENGINE AMERICA CORPORATION, Service Department at 1-800- 532-9808, kea_g.eewri@kubota.com or KUBOTATRACTOR CORPORATION, National Service Department at 1-800-558-2682, KubotaEmissionsWarranty@kubota.com or KUBOTA CANADA LTD at (905) 294-7477.

COVERAGE KUBOTA warrants to the initial purchaser and each subsequent purchaser that your engine will be designed, built and equipped, at the time of sale, to meet all applicable regulations. KUBOTA also warrants to the initial purchaser and each subsequent purchaser that your engine shall be free from defects in materials and workmanship which cause the engine to fail to conform to applicable regulations for the period mentioned above from the original date of sale.

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WARRANTY

KUBOTA shall remedy warranty defects at any authorized KUBOTA engine dealer or warranty station. Any authorized work done at an authorized dealer or warranty station shall be free of charge to the owner if such work determines that a warranted part is defective. Any KUBOTA approved or equivalent replacement part (including any KUBOTA approved aftermarket part) may be used for any warranty maintenance or repairs on emission related parts, and must be provided free of charge to the owner if the part is still under warranty.

KUBOTA is liable for damages to other engine components caused by the failure of a warranted part still under warranty. The use of replacement parts not equivalent to the original parts may impair the effectiveness of your engine emission control system. If such a replacement part is used in the repair or maintenance of your engine, and KUBOTA determines it is defective or causes a failure of a warranted part, your claim for repair of your engine may be denied.

Listed below are the parts covered by the Federal and California Emission Control Systems Warranty. Some parts listed below may require scheduled maintenance and are warranted up to the first scheduled replacement point for that part. The warranted parts are (if applicable):

1. Air-Induction System

a. Intake Manifold

b. Turbocharger System

c. Charge Air Cooling System (Intercooler)

2. Catalyst or Thermal Reactor System

a. Catalytic converter

b. Exhaust manifold

3. Fuel Injection System

a. Fuel Supply Pump (Common Rail System)

b. Injector

c. Injection Pipe

d. Common Rail

e. Smoke Puff Limiter

f. Speed Timer

g. Cold Advance Timer

h. Injection Pump

4. Electronic Control System

a. ECU

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WARRANTY

b. Engine Speed / Timing Sensor

c. Accelerator Position Sensor

d. Coolant Temperature Sensor

e. Atmospheric Pressure Sensor

f. Intake Pressure Sensor

g. Intake Manifold Temperature Sensor

h. Intake Air Flow Sensor

i. Common Rail Pressure Sensor

5. Exhaust Gas Recirculation System

a. EGR Valve

b. EGR Cooler

c. EGR Valve Opening Rate Sensor

6. Particulate Controls

a. Any device used to capture particulate emissions.

b. Any device used in the regeneration of the particulate control device.

c. Control Device Enclosures and Manifolding

d. Diesel Particulate Filter Temperature Sensor

e. Differential Pressure Sensor

7. Advanced Oxides of Nitrogen (NOx) Controls

a. Selective Catalytic Reduction (SCR) Catalyst

b. Reductant (urea) Containers

c. Dispensing Systems

d. NOx Sensor

e. SCR Temperature Sensor

f. Any Sensor for Diesel Exhaust Fluid

8. Miscellaneous Items

a. Closed Breather System

b. Hoses*, Clamps*, Fittings, Tubing*

c. Gaskets, Seals

d. Kubota supplied engine Wiring Harnesses

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WARRANTY

e. Kubota supplied engine Elec. Connectors

f. Air Cleaner Element*, Fuel Filter Element*

g. Emission Control Information Labels

*Warranty period is equivalent to manufacturer's recommended first replacement interval as stated in the applicable model's operator's manual and/ or service (workshop) manual.

MAINTENANCE REQUIREMENTS The owner is responsible for the performance of the required maintenance as defined by KUBOTA in the operators manual.

LIMITATIONS This Emission Control System Warranty shall not cover any of the following;

(a) Repair or replacement required because of misuse or neglect, improper maintenance, repairs improperly performed or replacements not conforming to KUBOTA specifications that adversely affect performance and/or durability, and alteration or modifications not recommended or approved in writing by KUBOTA.

(b) Replacement of parts and other services and adjustments necessary for required maintenance at and after the first scheduled replacement point.

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. The California evaporative emissions control system limited warranty statement below applies to your Off Highway Recreational Vehicle in California if the vehicle is equipped with an evaporative emission control system and is labeled with a Vehicle Evaporative Emissions Control Information label indicating that the vehicle conforms to California evaporative emissions regulations applicable to new off-road sport vehicles, all-terrain vehicles, or off-road utility vehicles. These vehicles are referred to as OHRV-EVAP below.

CALIFORNIA EMISSION CONTROLWARRANTY STATEMENT YOURWARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Polaris Industries Inc. is pleased to explain the emission control system warranty on your model year 2018 and newer Off Highway Recreational Vehicle. In California, new off-highway recreational vehicles must be designed, built and equipped to meet the State's

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WARRANTY

stringent anti-smog standards. Polaris must warrant the emission control system on your OHRV-EVAP for the periods of time listed below provided there has been no abuse, neglect or improper maintenance of your OHRV-EVAP.

Your emission control system may include parts such as the carburetor or fuel injection system, fuel tank, fuel hoses, carbon canister, engine computer and Evaporative Emissions Control System parts listed in the U.S.A. EPA Emissions Limited Warranty. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, Polaris will repair your OHRV-EVAP at no cost to you including diagnosis, parts and labor.

MANUFACTURERS WARRANTY COVERAGE: For model year 2018 and newer OHRV-EVAP models.

For 30 months, or 2500 miles, or 250 hours, whichever comes first, except for evaporative components over the OHRV high-priced warranty value, which is covered for 60 months, or 5000 miles, or 500 hours, whichever comes first.

If any emission-related part on your OHRV-EVAP is defective, the part will be repaired or replaced by Polaris.

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.

ADD-ON OR MODIFIED PARTS An add-on or modified part must be compliant with applicable CARB emission control standards. A violation of this requirement is punishable by civil and/or criminal punishment.

If you have any questions regarding your warranty rights and responsibilities, you should contact Polaris Customer Assistance at 1-800-POLARIS (1-800-765- 2747) or the California Air Resources Board at 9528 Telstar Avenue, El Monte, CA 91731.

United States & Canada: 1-800-POLARIS (1-800-765-2747)

French: 1-800-268-6334

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182

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

DATE MILES (KM) OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

184

4x2 Differential Lock Switch ......... 35

A Adding or Changing Coolant ...... 123 Additional Technical Fuel Requirements ......................... 62 Adjustable Steering Wheel .......... 31 Age Restrictions ........................ 20 Air Filter / Air Box..................... 155 Air Filter Replacement .............. 134 Alarm Belt Spin............................... 37 Park Brake ............................ 33 Reverse Alert Beeper .............. 32

Alternator Belt......................... 136 Auxiliary Outlets ........................ 31 Axle and Wheel Nut Torque Specifications........................ 145

B Battery .................................. 151 Battery Charging ..................... 152 Battery Installation ................... 151 Battery Removal...................... 151 Battery Storage ....................... 152 Belt Inspection ........................ 129 Belt Removal .......................... 127 Belt Spin Alarm ......................... 37 Belt Warning............................. 17 Bio-Diesel Blended Fuel.............. 67 Bio-Diesel Fuels ........................ 63 Brake Lights ........................... 149 Brake Pedal ............................. 36 Brake System Break-in ............... 57 Brakes .................................. 142 Braking ................................... 70 Break-in Period ......................... 57

C California Residents ................. 180 Clean the Exterior .................... 155 Clutch Cover Warning................. 16

Cold Weather Operation.............. 66 Component Locations................. 29 Console................................... 30 Cooling System....................... 123 Crossing Hillsides ...................... 22

D Demand Change Oil Change ..... 122 Descending Hills Improperly ........ 22 Diagnostic Display Code Definitions .............................. 53 Drive Belt Installation .......................... 130

Drive Belt Wear/Spin ................ 165 Drivetrain Break-in ..................... 57 Driving Downhill ........................ 74 Driving in Reverse ..................... 76 Driving on a Sidehill ................... 74 Driving on Slippery Surfaces ........ 73 Driving Over Obstacles ............... 76 Driving Procedures .................... 72 Driving Through Water................ 75 Driving Uphill ............................ 73 Driving with a Passenger............. 72 Dumping the Cargo Box .............. 81

E Electromagnetic Interference ....... 93 Electronic Power Steering ........... 37 Engine and Drivetrain Break-in ..... 57 Engine Backfires ..................... 167 Engine Doesn't Turn Over ......... 166 Engine Oil ...............................113 Engine Oil / Filter Change...........117 Engine Oil Check......................115 Engine Pings or Knocks ............ 167 Engine Runs Irregularly, Stalls or Misfires ............................ 168 Engine Stops or Loses Power .... 169 Engine Turns Over, Fails to Start .................................... 166 European Vibration and Noise ........7 Exhaust Emission Control System .................................. 93

185

Exported Products ................... 175 Exposure to Exhaust .................. 26

F Failure to Inspect Before Operating ............................... 20 Fan, Cooling........................... 123 Fluid Levels............................ 155 Fuel Cap.................................. 38 Fuel Filter / Water Separator ...... 136 Fuel Recommendations .............. 61 Fuel Transport Warning............... 14 Fuses ................................... 150

G Gear Selector ........................... 32 Gearcase Specification Chart ..... 120

H Handling Fuel ........................... 65 Hauling Cargo........................... 78 Headlight Beam Adjustment....... 149 Headlights Bulb Replacement ................ 147

Hitch Capacity Label .................. 17 Hood Latches ........................... 38 Hot Exhaust Systems ................. 26 How To Obtain Warranty Service ................................ 174

I Idle RPM ............................... 138 Ignition Switch .......................... 34 Improper Cargo Loading ............. 25 Improper Tire Maintenance .......... 21 Inspect and Lubricate ............... 156 Instrument Cluster Back Light Color ..................... 49 Back Light Level ..................... 50 Clock ................................... 48

Diagnostic Code..................... 52 Display Area 1 ....................... 43 Display Area 2 ....................... 44 Indicator Lamps ..................... 41 Options Menu ........................ 45 Overview .............................. 40 Service Hours ........................ 51 Unit Selection Distance............ 46 Unit Selection Temperature....... 47

L Light Switch.............................. 34 Lights.................................... 147 Limited Warranty ..................... 171 Load Capacity........................... 79 Load/Passenger/Tire Pressure Warning ................................. 15 Lubrication Recommendations ....113

M Maintenance Intervals ................ 95 Maintenance Log..................... 183 Modifications to Vehicle .............. 27

N Noise Emission Control System.... 93

O Obstacles ................................ 76 Occupant Protection Structure (OPS).................................... 38 Oil / Filter Change.....................117 Oil and Filter ........................... 155 Oil Check................................115 Oil Recommendations ...............114 Operating Conditions.................. 68 Operating Improperly in Reverse... 23 Operating Over Obstacles ........... 24 Operating Through Water ............ 24

186

Operating With a Load on the Vehicle .................................. 21 Operating Without Instruction ....... 19 Operation on Public Lands in the U.S.A................................ 93 Outlets .................................... 31 Overflow Bottle Coolant Level .... 125

P Park Brake Lever....................... 33 Alarm................................... 33

Parking on an Incline .................. 77 Parking the Vehicle .................... 77 Periodic Maintenance Chart ......... 95 Personal Protective Equipment..... 11 POLARIS PRODUCTS ............. 163 POLARIS Variable Transmission (PVT) Drying ...... 132 POLARIS Variable Transmission System.............. 126 Polishing the Vehicle ................ 155 Poor Visibility............................ 25 Power Steering Unit (Cleaning)... 146 Pre-Ride Inspection ................... 59 Proper Use Warning (2000D) ....... 14 Proper Use Warning (4000D) ....... 14 Pulley Warning.......................... 16 Pulse Bar................................. 35 PVT Break-in (Clutches/Belt) ....... 58

R Radiator and Cooling Fan.......... 123 Radiator Coolant Level ............. 124 Rear Differential System ............. 71 Refueling ................................. 65 Registration, Warranty .............. 171 Removal from Storage.............. 156 Reverse Alert Beeper ................. 32 Reverse Operation..................... 76

S Safe Operation Practices ............ 58

Safety Labels and Locations ........ 12 Safety Symbols ...........................8 Safety, Winch Maintenance.......... 92 Seat and Storage Compartments ........................ 37 Seat Belt / Drive Responsibly Warning ................................. 13 Seat Belts ........................... 20, 39 Service Intervals Maintenance ......................... 95

Shift Caution............................. 16 Shock Loading the Winch ............ 91 Signal Words ..............................8 Specifications 2000D................................ 159 4000D................................ 161

Spring Adjustment ................... 144 Stalling While Climbing a Hill ........ 23 Starting the Engine .................... 69 Steering Wheel Adjustment ......... 31 Steering Wheel Inspection......... 143 Stopping the Engine................... 70 Storage ................................. 155 Storage Area .......................... 156 Switches Light Switch........................... 34

T Throttle Cable Adjustment.......................... 139

Throttle Freeplay ..................... 138 Throttle Freeplay Inspection....... 138 Throttle Pedal ........................... 36 Adjustment.......................... 140

Throttle System....................... 138 Tire Rotation........................... 145 Tire Tread Depth ..................... 144 Tires ..................................... 144 Towing a PRO XD.................... 158 Towing Loads ........................... 80 Trailer Capacity Label................. 17 Trailer Hitch Bracket................... 38 Transmission Oil Change .......... 121 Transmission Oil Check ............ 120 Transporting the PRO XD.......... 157 Turning Improperly..................... 22

187

U Unauthorized Use of the Vehicle ... 26

V Vehicle Identification Numbers .......9 Vehicle Immersion ................... 133

W Warning Symbols ........................8 Warranty Coverage And Exclusions Lubricants and Fluids ............ 173

Washing the Vehicle................. 154 Water Separator ...................... 136 Wheel Installation .................... 146 Wheel Removal....................... 146 Wheel, Steering Adjustment............................ 31

Winch Cable Care ..................... 90 Winch Maintenance and Service Safety ......................... 92 Winch Operation ....................... 85 Winch Safety Precautions ........... 83 Winch Shock Loading................. 91

188

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

or visit www.polaris.com

Manualsnet FAQs

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