Polaris PRO XD 2000G, 4000G Owner's Manual PDF

Pages 174
Year 2020
Language(s)
English en
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Summary of Content for Polaris PRO XD 2000G, 4000G Owner's Manual PDF

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POLARIS PRO XD 2000G POLARIS PRO XD 4000G

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

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

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Introduction ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 7 Safety ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 11 Features and Controls ... ... ... ... ... ... ... ... ... ... ... ... ... ... 31 Operation ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 65 Winch Guide... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 85 Emission Control Systems ... ... ... ... ... ... ... ... ... ... ... ... ... 95 Maintenance ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 97 Specifications ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 143 POLARIS Products ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 149 Troubleshooting ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 151 Warranty ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 155 Maintenance Log ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... ... 165

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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...

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PROPER USE WARNING (2-SEAT) WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries: Do not allow careless or reckless driving...

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MODEL NEVER EXCEED IF TOTAL PAYLOAD EXCEEDS

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Part Number: 7186122 WARNING NEVER carry fuel or other flammable liquids on this vehicle Failure to follow this instruction could lead to serious burn injuries or death...

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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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Part Number: 7177469 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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Part Number: 7300087 CAUTION 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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Always remove the key when leaving the vehicle unattended... Never consume alcohol or drugs before or while operating this vehicle... Never operate at excessive speeds... Always operate at a speed that's appropriate for the traffic, the visibility and operating conditions, your skills and your passengers skills...

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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

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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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system... Use caution when traveling through tall grass, especially dry grass, and when traveling in muddy conditions... Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush, other tall ground cover, and muddy conditions... Promptly remove any grass, debris, or foreign matter clinging to the vehicle... Pay particular attention to the

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

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

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

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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 151...

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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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PULSE BAR The Pulse Barq 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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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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FUEL CAP The fuel tank filler capq is located on the left-hand side of the vehicle near the drivers seat... To close, tighten the fuel cap until it clicks twice... When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane... Do not use fuel with ethanol content greater than 10 percent, such as E-85 fuel... Always ensure that the fuel tank filler cap is fully tightened and secure before operating or transporting the vehicle...

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SEAT BELTS This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all seats... Always make sure the seat belts are secured for all riders before operating... The drivers seat belt is equipped with a seat belt interlock... Vehicle speed will be limited to 15 miles per hour if the seat belt is not secured...

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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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5... If the correct PIN is entered, you will enter the Adjustable Speed Limiting menu... The screen will read MAX SPEED and will either display the currently set max speed or the word OFF if there is no max speed currently set... From here, you can use the up and down buttons to navigate to the CHANGE PIN screen and the EXITscreen... (If you want to exit the Adjustable Speed Limiting Menu, press the MODE button on the EXITscreen... )

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b... Use the up and down buttons to toggle between the different settings: 15 MPH, 20 MPH, 25 MPH, 30 MPH, 35 MPH, or OFF... When MAX SPEED is set to OFF, the vehicles max speed is 40 MPH...

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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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DIAGNOSTIC DISPLAY CODE DEFINITIONS Open Load:There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc... ), or the item has failed...

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Starter Enable Circuit Driver Circuit Open/ Grounded 1321 5

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Chassis Relay Driver Circuit Open/ Grounded 520208 5

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

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Data Valid But Above Normal Operating Range - Moderately 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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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, foreign matter, and other flammable material or debris, especially near the exhaust system...

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

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Press the top of the switch to engage All Wheel Drive (AWD)... The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD... When the AWD switch is on, 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... There is no limit to the length of time the vehicle may remain in AWD... Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100... Once enabled, the AWD remains enabled until the AWD switch is turned off... If the switch is turned off while the front gearcase is moving, it will not disengage until the rear wheels regain traction...

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

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

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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 serious injury... The box could close unexpectedly and cause injury to the driver or

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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 93... 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 OVERVIEW 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... 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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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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XU - PERFORM THESE PROCEDURES MORE OFTEN FOR VEHICLES SUBJECTED TO SEVERE USE... D - HAVE AN AUTHORIZED POLARIS DEALER OR OTHER QUALIFIED PERSON PERFORM THESE SERVICES... E - EMISSION CONTROL SYSTEM SERVICE (CALIFORNIA)

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

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NOTE 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 dipstick and oil fill cap by tilting the rear cargo box...

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9... 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... Install it to specification...

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

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

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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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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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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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5... Install the clutch cover into wheel well by installing the top half first, then the bottom half over the suspension...

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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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FILTER SYSTEMS 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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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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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...

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

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

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

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Front Suspension Dual A-arm w/ 9 in... (22... 86 cm) of travel

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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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Front Suspension Dual A-arm w/9 in... (25... 4 cm) of travel

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

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POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS

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

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Fouled or defective spark plug Inspect plug and replace if necessary

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

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Overheated engine Clean radiator screen and core, clean engine exterior... Your dealer can assist...

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

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

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

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

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

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The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers (3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... The warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first... This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole... The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension, but emission-related parts may be covered subject to the terms of any such paid service contract or paid warranty extension...

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Emission-related components also include any other part whose only purpose is to reduce emissions or whose failure will increase emissions without significantly degrading engine/equipment performance... The exclusive remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products... THE REMEDIES SET FORTH IN THIS LIMITED WARRANTYARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY... POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OFANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE... THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE...

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

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

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

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E Electromagnetic Interference ... 95 Electronic Power Steering ... 39 Emissions Limited Warranty... 160 Engine and Drivetrain Break-in ... 65 Engine Backfires ... 152 Engine Doesn't Turn Over ... 152 Engine Oil ... 106 Engine Oil and Filter Replacement ... 108 Engine Pings or Knocks ... 153 Engine Runs Irregularly, Stalls or Misfires ... 153 Engine Stops or Loses Power ... 154 Engine Turns Over, Fails to Start ... 152 Exhaust Emission Control System ... 95 Exported Products ... 159 Exposure to Exhaust ... 28

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I Ignition Switch ... 35 Improper Cargo Loading ... 27 Improper Tire Maintenance ... 23 Inspect and Lubricate ... 141 Instrument Cluster Adjustable Speed Limiting ... 56 Back Light Color ... 53 Back Light Level ... 54 Clock ... 51 Diagnostic Code... 58 Display Area 1 ... 45 Display Area 2 ... 46 Indicator Lamps ... 43

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Safety Labels and Locations ... 12 Safety Symbols ... 8 Safety, Winch Maintenance... 94 Seat and Storage Compartments ... 39 Seat Belt / Drive Responsibly Warning ... 12 Seat Belts ... 22, 41 Shift Caution Label ... 19 Shock Loading the Winch ... 93 Signal Words ... 8 Spark Arrester ... 126 Spark Plug Gap/Torque... 112 Spark Plug Inspection... 112 Spark Plug Recommendations ... 112 Specifications 2000G... 143 4000G... 145

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Winch Cable Care ... 92 Winch Maintenance and Service Safety ... 94 Winch Operation ... 87 Winch Safety Precautions ... 85 Winch Shock Loading... 93

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

Manualsnet FAQs

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

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