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

Pages 192
Year 2019
Language(s)
English en
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Summary of Content for Polaris PRO XD 2000D 4X2, 2000D AWD, 4000D AWD Owners Manual Owner's Manual PDF

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

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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

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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...

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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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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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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...

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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...

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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...

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

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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...

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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...

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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...

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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...

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BELT WARNING WARNING Improper service or maintenance of this PVTsystem can result in vehicle damage, SEVERE INJURYor DEATH...

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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...

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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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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...

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Do not exceed vehicle weight capacities... The vehicles maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle... When determining the weight you are adding to the vehicle, include the weight of the operator, accessories, loads in the rack or box and the load on the trailer tongue... The combined weight of these items must not exceed the maximum weight capacity...

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

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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...

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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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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

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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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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...

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

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

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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...

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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

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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...

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

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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...

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

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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...

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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...

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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...

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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...

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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...

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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...

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

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

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Diagnostic Codes Only displays if fault codes are present or stored

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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...

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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...

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

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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...

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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...

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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...

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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...

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

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

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Data valid but below normal operating range - least severe level

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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...

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

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

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

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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...

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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...

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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:

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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...

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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...

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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...

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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...

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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...

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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...

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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...

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

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

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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:

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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

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

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2... When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights...

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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

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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...

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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...

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

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

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

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

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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

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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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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:

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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...

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

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

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

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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/...

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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...

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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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

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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...

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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:

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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

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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...

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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...

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

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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...

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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...

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

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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...

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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...

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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)...

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

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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...

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

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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...

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

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

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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:

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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...

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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...

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

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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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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...

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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...

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

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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)...

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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...

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store or use a partial bottle... Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air... The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of

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

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

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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...

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

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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...

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

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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...

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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...

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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...

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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...

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25%-50% 11... 5-12... 0 volts Needs charge At least 13 hours, verify state of charge

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

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

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STORAGE AREA / COVERS Be sure the storage area is well ventilated... Cover the vehicle with a genuine POLARIS cover... Do not use plastic or coated materials... They do not allow enough ventilation to prevent condensation, and may promote corrosion and oxidation...

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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)...

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

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

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54 inches wide, 43... 5 inches long, 11... 5 inches high (137 cm wide, 110 cm long, 29 cm high)

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

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2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (3... 8 l/1 gal... )

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

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

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Old or non-recommended fuel Replace with fresh recommended fuel

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ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION

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

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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...

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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...

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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...

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IF YOU MOVE: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move... Product importation rules vary considerably from country to country... You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage... You may also be required to obtain documentation from POLARIS in order to register your product in your new country... You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle...

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

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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...

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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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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...

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

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CALIFORNIA RESIDENTS Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions... Only the 50-state models are certified for sale in California... The 50- state models available for sale in California are identified by the letter B in the ninth position of the model number (e... g... , R16RTE87B)... The POLARIS 50-state models are designed and built with features such as a reduced cargo box capacity... Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer... 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...

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

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

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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

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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

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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

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

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

Manualsnet FAQs

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