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

Pages 198
Year 2021
Language(s)
English en
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Summary of Content for Polaris PRO XD 2000D AWD, 4000D AWD Owner's Manual PDF

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POLARIS PRO XD 2000D AWD POLARIS PRO XD 4000D AWD

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Copyright 2020 Polaris, Inc... All information contained within this publication is based on the latest product information at the time of publication... Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication... Depictions and/or procedures in this publication are intended for reference use only... No liability can be accepted for omissions or inaccuracies... Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited...

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

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Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... 33 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 63 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 89 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 99 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 101 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 167 POLARIS Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 171 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 173 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 177 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 189

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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...

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

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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...

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

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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... Use caution while operating vehicle on private paved surfaces... Pavement can alter handling and may cause loss of control...

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Part Number: 7300098 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...

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WARNING Part Number: 7186122 NEVER carry fuel or other flammable liquids on this vehicle...

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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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VEHICLE RATED CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSEN- GER, CARGO, AND ACCESSO- RIES...

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Improper service or maintenance of this CVTsystem 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 an authorized service dealer...

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CAUTION Part Number: 7300087 To avoid transmission damage, shift only when vehicle is stationary and at idle... When vehicle is stopped, place gear selector in PARK...

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WARNING Part Number: 7182156 Moving parts present... Keep hands away from moving parts to prevent injury...

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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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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

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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, passengers, 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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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...

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

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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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The addition of certain accessories, including (but not limited to) overhead audio speakers, may change the forward clearance in the vehicle... Polaris recommends selecting a helmet that is compatible with the equipment on your vehicle and provides the greatest amount of forward clearance... Always wear a helmet that meets or exceeds the specifications in this owners manual... Refer to the Safe Riding Gear section of this owners manual for more information... Use only POLARIS-approved accessories...

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tMuffler (Spark Arrester) y Receiver Hitch u CV Boot / Rear Caliper

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y Park Brake u Horn Switch i Drivers Side Auxiliary Outlet o Passenger Side Auxiliary Outlet a Storage Compartment

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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 4000 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... 4000 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 173...

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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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AWD SWITCH (IF EQUIPPED) The AWD switch has three positions: All Wheel Drive (AWD), Differential Lock/Two Wheel Drive (2WD) and Off (1WD/Turf Mode)... Press the top of the switch to engage All Wheel Drive (AWD)... Move the switch to the center position to lock the differential and operate in two wheel drive (2WD)... Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently (1WD)... This mode of operation is well suited to turf driving or when active traction is not needed...

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SEATAND 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...

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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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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...

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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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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 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...

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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 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...

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

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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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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...

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Air Filter Inspect air filter, ensure it is properly installed; ensure air box cover is secured and fastened... Note: Air filter removal is not needed for visual inspection...

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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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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...

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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 +5 F (-15 C) to -25 F (-32 C) 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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AWD VEHICLE OPERATION All Wheel Drive (AWD) is active at all times on the Polaris PRO XD 2000D AWD and the Polaris PRO XD 4000D AWD... The front gearcase will automatically engage any time the rear wheels lose traction... When the rear wheels regain traction, the front gearcase will automatically disengage...

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

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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...

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

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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

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

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

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11... The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck... The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle... See the Shock Loading section on page 97... For your safety, always follow these guidelines when winching a vehicle free:

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

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

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

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

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

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

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MAINTENANCE INTERVALS The maintenance interval charts list required maintenance and inspection based on vehicle hours / miles... Each table states a service that corresponds to the hour / mile chart below... Some items or components may need to be serviced more often due to severe use, such as operation in water, extreme temperatures, or under severe loads...

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XU / E Engine Oil & Filter Change Inspect oil level (Break-in oil and filter change at first 50 hrs; perform every 200 hrs, thereafter)

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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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D / E Fuel System Turn key on to pressurize fuel pump; check lines and fittings for leaks and abrasion,Check for leaks at fill cap, and fuel pump...

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

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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...

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

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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...

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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...

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GREASE LUBRICATION POINTS There are grease fittings at the rear stabilizer bar bushings and on the front propshaft yokes... Apply grease until all traces of water have been purged out at each of these areas...

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Rear Stabilizer Bar Bushings, Right and Left Side

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

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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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FUEL LEAK INSPECTION 1... Lift the drivers seat and the box to gain access to the fuel lines...

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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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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

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

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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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SHIFT CABLE / LINKAGE INSPECTION Ensure that shift cable/linkage is clean, free of debris, operation is smooth and cable boot is not damaged... If operation is not smooth or if the cable boot is damaged or torn, contact an authorized dealer for service...

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

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Use the following procedure to periodically purge accumulated carbon from the exhaust pipe...

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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 lb (89) of force is applied to the belt...

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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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7... Unscrew the drain value 1/2 to 1 full turn until fuel starts to drain from the bottom do NOT unscrew the valve completely...

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5... Unscrew fuel filter / water separatorq from the filter mount using a commercially available filter wrench if not able to remove by hand...

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11... Start engine and verify that no fuel leaks are present...

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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...

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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 1/161/8 in (1... 63... 2 mm)...

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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...

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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...

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

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

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2... Check for any looseness in front wheel/hub assembly by grasping the tire firmly at top and bottom first, and then at front and rear... Try to move the wheel and hub by pushing inward and pulling outward...

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AXLE INSPECTION Inspect inboard and outboard boots on both sides of the vehicle, frontq and rearw, for tears... If a tear is discovered, have the boot replaced by an authorized dealer...

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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 1/8 in (3 mm) 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...

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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 8 in (20 cm) below the mark placed on the wall... Include the weight of a rider on the seat while performing this step...

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2... Depress the brake pedal... The brake light should come on after about 0... 4 in (10 mm) 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 battery q... 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 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...

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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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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 lb (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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2075 lb (941 kg) (including operator, passengers, cargo, accessories)

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

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2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid 1 qt (0... 95 L)

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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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Loose ignition connections Check all connections and tighten

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

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This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; use of unapproved software or calibration; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center...

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THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OFANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS... THE REMEDIES SET FORTH IN THIS WARRANTYARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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

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

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KUBOTA CORPORATION FEDERAL & CALI- FORNIA EMISSION CONTROL SYSTEMS LIM- ITED WARRANTY 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...

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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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(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...

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

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

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

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B Battery ... 159 Battery Charging ... 160 Battery Installation ... 159 Battery Removal... 159 Battery Storage ... 160 Belt Inspection ... 127 Belt Removal ... 125 Belt Spin Alarm ... 41 Bio-Diesel Blended Fuel... 72 Bio-Diesel Fuels ... 68 Brake Fluid... 146 Brake Inspection ... 147 Brake Lights ... 157 Brake Pedal ... 40 Brake System Break-in ... 64 Brakes ... 146 Braking ... 75 Break-in Period ... 63 Break-In Period ... 101

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Inspect and Lubricate ... 164 Instrument Cluster Back Light Color ... 55 Back Light Level ... 56 Clock ... 53 Diagnostic Code... 58 Display Area 1 ... 47 Display Area 2 ... 48 Indicator Lamps ... 45 Options Menu ... 50 Overview ... 44 Service Hours ... 57 Unit Selection Distance... 51 Unit Selection Temperature... 52

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O Obstacles ... 82 Occupant Protection Structure (OPS)... 41 Oil / Filter Change... 111 Oil and Filter ... 163 Oil Check... 109 Oil Recommendations ... 108 Operating Conditions... 73 Operating Improperly in Reverse... 27 Operating Over Obstacles ... 28 Operating Through Water ... 28 Operating With a Load on the Vehicle ... 25 Operating Without Instruction ... 23 Operation on Public Lands in the U... S... A... 99 Outlets ... 35 Overflow Bottle Coolant Level ... 122

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Throttle System... 141 Tire Rotation... 152 Tire Tread Depth ... 151 Tires ... 151 Towing a PRO XD... 166 Towing Loads ... 85 Trailer Hitch Bracket... 42 Trailer/Hitch Capacity ... 20 Transmission Oil Change ... 116 Transmission Oil Check ... 115 Transporting the PRO XD... 165 Turning Improperly... 26

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For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www... polaris... com

Manualsnet FAQs

If you want to find out how the 4000D AWD Polaris works, you can view and download the Polaris PRO XD 2000D AWD, 4000D AWD Owner's Manual on the Manualsnet website.

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