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Polaris RZR XP 1000 v3 Owner's Manual PDF
Summary of Content for Polaris RZR XP 1000 v3 Owner's Manual PDF
PMS 419
Owner's Manual for Maintenance and Safety
Read this manual carefully. It contains important safety information. This is an adult vehicle only.
Operation is prohibited for those under 16 years of age.
2015 RZR XP 1000
For videos and more information about a safe riding experience with your Polaris vehicle, scan this QR
code with your smartphone.
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WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. Snowmobiles All-terrain vehicles (ATVs) Low emission vehicles (LEVs) RANGER utility vehicles RZR sport vehicles VICTORY motorcycles GEM electric vehicles Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service Dealer (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.
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POLARIS and RZR are trademarks of POLARIS Industries Inc. Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2015 RZR XP 1000 Owners Manual P/N 9926049
For a closer look at your RZRs features and recommended maintenance, scan this QR code with your smartphone.
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TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 25 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Emission Control Systems . . . . . . . . . . . . . . . 80 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 132 POLARIS Products. . . . . . . . . . . . . . . . . . . . . 134 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 135 Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 143 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
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INTRODUCTION The RZR is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. 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.
The safety alert symbol indicates a potential personal injury hazard.
DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
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INTRODUCTION Declaration of Conformity
Polaris Sales Europe Srl Route de IEtraz Business Center A5 1180 Rolle, Switzerland Telephone +41213-218-700
DECLARATION OF CONFORMITY January 1, 2015 Polaris Sales Europe Srl declares that the vehicle(s) listed below conform to the essential requirements applicable to all terrain vehicles.
APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS
2006/42/EC as amended (Machinery Directive)
EN 15997 Noise & Vibration Level
2004/108/EC as amended (EMC Directive)
UNECE R10 97/24/EC Chapter 8
MODEL COMMERCIAL NAME SERIAL NUMBER
Z_ _VD _ 99 _ (All combinations)
RZR XP 1000 TAPVD_ _ 99_ F_ _ _ _ _ _ _ (All combinations)
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INTRODUCTION Vehicle Identification Numbers Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Vehicle Identification Number: ______________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
Engine Serial Number
Key Number
Vehicle Identification
Number
####
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SAFETY
Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
Read this owners manual and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.
Never operate this vehicle without proper instruction. Take an authorized training course.
Complete the New Operator Driving Procedures outlined on pages 56-57. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures.
This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid drivers license to operate this vehicle.
No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.
Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other body parts inside the vehicle at all times.
Always wear a seat belt when riding in this vehicle. Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.
Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time.
Safety Training Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course. For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com. Your POLARIS vehicle is considered an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. We strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
WARNING
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SAFETY Safe Riding Gear The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury. Helmet Wearing a helmet can prevent a severe head injury. Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
E4
051039 0006.31
Helmet
Eye Protection
Gloves
Over-the-Ankle Boots
Long Pants
Long Sleeves
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SAFETY Safe Riding Gear Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean. Gloves Wear gloves for comfort and for protection from sun, cold weather and other elements. Boots Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals. Clothing Wear long sleeves and long pants to protect arms and legs.
Rider Comfort Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the driver and passenger cab area. The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow. Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow.
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SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
Proper Use Warning WARNING Require Proper Use of Your Vehicle Do your part to prevent injuries:
Do not allow careless or reckless driving.
Make sure operators are 16 or older with a valid drivers license.
Do not let people drive or ride after using alcohol or drugs.
Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.
Do not exceed seating capacity: 2 occupants.
Proper Use Warning
Seat Belt Warning
Drive Responsibly Warning
Riders Warning
Payload Warning
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SAFETY Safety Labels and Locations Drive Responsibly Warning Drive Responsibly Avoid loss of control and rollovers: Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts. Slow down before entering a turn. Avoid hard acceleration when turning, even
from a stop. Plan for hills, rough terrain, ruts and other
changes in traction and terrain. Avoid paved surfaces. Avoid sidehilling (riding across slopes).
7179761
Payload Warning WARNING
Riders Warning Be Sure Riders Pay Attention and Plan Ahead If you think or feel the vehicle may tip or roll, reduce your risk of injury: Keep a firm grip on the steering wheel or hand holds and brace yourself. Do not put any part of your body outside of the vehicle for any reason.
7179762
Seat Belt Warning WARNING Improper vehicle use can result in SEVERE INJURY or DEATH Be Prepared Fasten seat belts. Wear an approved helmet and protective gear. ALWAYS use cab nets and/or doors. Each rider must be able to sit with back against seat, feet flat on the floor, and
hands on steering wheel or hand holds. Stay completely inside the vehicle. LOCATE AND READ OWNERS MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org).
7179499
RZR Never Exceed If Total Payload Exceeds XP 1000 109 km/h 195 kg
Rollovers have caused severe injuries and death, even on flat, open areas.
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SAFETY Safety Labels and Locations Load/Passenger/Tire Pressure Warning WARNING Passengers can be thrown off. This
can cause serious injury or death. Never carry passengers in cargo
box.
WARNING IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
Reduce speed and allow greater distance for braking when carrying cargo.
Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box.
For stability on rough or hilly terrain, reduce speed and cargo. Be careful if load extends over the side of the box.
RZR XP 1000 MAXIMUM CARGO BOX LOAD 136 kg (300 lbs.)
TIRE PRESSURE IN KPa (PSI) FRONT 110 (16) REAR 110 (16)
MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGER, CARGO AND ACCESSORIES
336 kg (740 lbs.)
Read Operation and Maintenance Manual for more detailed loading information.
Load/Passenger/Tire Pressure Warning (in cargo box)
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SAFETY Safety Labels and Locations Belt Debris Warning WARNING Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH. Always look for and remove debris inside and around the clutch and vent system when replacing the belt. Read owners manual or see authorized POLARIS dealer.
7177469
Air Box Caution CAUTION Use a Polaris approved air filter. The use of a non-Polaris approved air filter may cause engine damage. Before installing filter, ensure there is no dirt or debris in the clean side of the intake tube. The air filter must be properly seated before the lid is reinstalled. Please reference your owners manual for additional information regarding air filter service.
Belt Debris Warning
Air Box Caution
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SAFETY Safety Warnings
Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owners manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owners manual for proper operating procedures.
Operating Without Instruction Operating this vehicle without proper instruction increases the risk of an accident. Take a training course and complete the New Operator Driving Procedures outlined on pages 56-57. All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 56-57.
Age Restrictions This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age or anyone without a valid drivers license. Never operate with a passenger under the age of 12. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.
Using Alcohol or Drugs Riding in this vehicle after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception. Never consume alcohol or drugs before or while operating or riding in this vehicle.
Rollovers A rollover can result in serious injury or death. Avoid operating in a manner that could result in a rollover.
WARNING
< 16
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SAFETY Safety Warnings Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident. Operator and all passengers must always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.
Seat Belts Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances.
All riders must wear seat belts at all times.
Cab Doors Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched while riding in this vehicle. Cab doors are NOT intended to be used as arm rests. Always keep hands and feet inside the vehicle at all times.
Operating on Public Roads Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). In some areas it's unlawful to operate this vehicle on public streets, roads and highways.
Jumps and Stunts Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, donuts, jumps or other driving stunts. Avoid exhibition driving.
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SAFETY Safety Warnings Failure to Inspect Before Operating 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 before each use of your vehicle to make sure it's in safe operating condition. See page 52. Always follow the inspection and maintenance procedures and schedules described in this owners manual. See page 81.
Carrying a Passenger Never carry a passenger until you have operated this vehicle for at least two hours and have completed the New Operator Driving Procedures outlined on pages 56-57. A passenger must always be seated in a passenger seat with seat belt secured. Carrying more than one passenger in a 2-seat vehicle can affect the operators ability to steer and operate the controls, which increases the risk of loss of control and accident or rollover. Never carry more than one passenger in a 2-seat vehicle.
Operating With a Load on the Vehicle The weight of both cargo and passengers impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.
Do not exceed vehicle weight capacities. The vehicles maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle. When more passenger weight is added, cargo weight may need to be reduced accordingly.
The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle.
Always follow these guidelines:
Under ANY of these conditions: Do ALL of these steps: Passenger and/or cargo exceeds half the maximum weight capacity
1. Slow down. 2. Verify tire pressure. 3. Use extra caution when
operating. Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing
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SAFETY Safety Warnings Passengers in the Cargo Box Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. A passenger must always be seated in a passenger seat with seat belt secured.
Operating on Pavement This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.
Operating at Excessive Speeds Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions, your skills and experience and your passengers skills and experience.
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SAFETY Safety Warnings Turning Improperly Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner's manual. Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.
Improper Hill Climbing Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See page 60.
Descending Hills Improperly Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owners manual. See page 61.
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SAFETY Safety Warnings Crossing Hillsides Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See page 61.
Stalling While Climbing a Hill Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill. If you lose all forward speed: Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.
Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover. Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
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SAFETY Safety Warnings Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 64. Before shifting into reverse gear, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.
Improper Tire Maintenance Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control, accident or rollover. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in this owner's manual and on safety labels.
Skidding or Sliding Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces. Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See page 59.
Operating Over Obstacles Improperly operating over obstacles could cause loss of control or rollover. Before operating in a new area, check for obstacles. Never attempt to operate over large obstacles such as large rocks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See page 63.
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SAFETY Safety Warnings Operating Through Water Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle. Always follow proper procedures for operating in water as described in this owners manual. See page 62. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
Operating on Frozen Bodies of Water Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passengers, and your cargo, together with any other vehicles in your party. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.
Operating a Damaged Vehicle Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems.
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SAFETY Safety Warnings Improper Cargo Loading Overloading the vehicle or carrying cargo improperly may cause changes in stability and handling, which could cause loss of control or an accident.
Always follow the instructions in this owners manual for carrying cargo. See page 66.
Never exceed the stated load capacity for this vehicle. See page 12.
Cargo should be properly distributed and securely attached. See page 66.
Reduce speed when carrying cargo. Allow a greater distance for braking.
Refueling Gasoline is highly flammable and explosive under certain conditions.
Always exercise extreme caution whenever handling gasoline.
Always turn off the engine when refueling.
Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.
Always use an approved gasoline container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge.
Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.
Do not overfill the tank. Do not fill the tank neck.
If gasoline spills on your skin or clothing, immediately wash it off with soap and water and change clothing.
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SAFETY Safety Warnings Exposure to Exhaust Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.
Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass, to avoid debris build-up around the exhaust system.
Unauthorized Use of the Vehicle Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.
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SAFETY Safety Warnings Equipment Modifications Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury. The warranty on your POLARIS vehicle will be terminated if any non-POLARIS- approved equipment and/or modifications have been added to the vehicle that increase speed or power. The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories, and familiarize yourself with their function and effect on the vehicle.
For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.
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FEATURES AND CONTROLS Component Locations
Cab DoorsFuel Tank
Cap
Cargo Box
Passenger Hand Hold
ROPS Frame
Radiator
Steering Wheel
Gear Selector
Throttle Pedal
Brake PedalCargo Box Tie-Down
Points (4 corners)
Mirror
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FEATURES AND CONTROLS Switches
Auxiliary Outlets The vehicle is equipped with one or more 12-volt accessory outlets. One outlet is on the dash, a second outlet (if equipped) is in the rear passenger area. Use the outlets to power an auxiliary light or other optional accessories. For service, the dash outlet connection is under the dash. The rear outlet connection is under the rear passenger seats.
Hazard Switch Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.
Hazard Switch
AWD Switch
12V Accessory OutletIgnition Switch
Instrument Cluster
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FEATURES AND CONTROLS Switches Ignition Switch/Light Switch Use the ignition switch to start the engine and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position.
High Beam Switch The headlight high beam is controlled by the turn signal lever. To switch the headlights to high beam, move the lever forward, toward the console. Pull the lever rearward to switch the headlights to low beam. When set on low beam, pull and release the lever for a momentary high beam.
Horn Switch The horn switch is located on the turn signal lever. Press the tip of the turn signal lever inward to sound the horn.
OFF Turn the key to the OFF position to stop the engine. Electrical circuits are off.
LIGHTS ON All lights are on. Electrical circuits are on. Electrical equipment can be used.
POSITION LIGHTS ON
The headlights are off. Position lights are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter. See page 54 for starting procedures.
Horn Switch
Turn Signal Lever
High BeamLow
Beam
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FEATURES AND CONTROLS Switches Turn Signal Lever Before turning, activate a turn signal to alert others of your intentions. Check turn signal lamps before each ride. Tip: The key must be in the ON
position to activate the turn signals.
Move the turn signal lever downward to signal a left turn. The left turn signal lamps in the taillight and below the front headlight will flash. The turn signal indicator in the gauge will also flash. Move the lever upward to signal a right turn. The right signal lamps and indicator will flash. Return the lever to the center position to end the signal.
All Wheel Drive (AWD) Switch The AWD Switch has three positions: All Wheel Drive (AWD) Two Wheel Drive (2WD) Turf Mode/Differential Unlocked
(1WD) See page 40 for AWD operating instructions.
Right Turn
Left Turn
AWD
Differential Lock (2WD)
Differential Unlock (1WD)
29
FEATURES AND CONTROLS Electronic Power Steering (EPS) Electronic power steering (if equipped) engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. The EPS warning indicator briefly illuminates when the key is turned to the ON position. See page 43. 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. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service.
Steering Wheel The steering wheel can be tilted upward or downward for rider preference. Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.
Mirrors Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the vehicle.
Adjustment Lever
30
FEATURES AND CONTROLS Seats Before operating the vehicle, always push down on all seat backs to ensure the latches are secure.
Seat Adjustments On seats equipped with an adjustment lever under the front edge of the seat, pull the lever to the left. Slide the seat forward or rearward to the desired position. Release the lever. The seat will lock into the new position. For other seat styles, loosen (do not remove) the four screws located on the seat bottom. Slide the seat forward or rearward to the desired position. Tighten the screws to 5.4 Nm. Do not overtighten.
Seat Removal 1. Pull up on the seat latch
lever located under the rear edge of the seat.
2. Tilt the seat forward. 3. Lift the seat upward to
remove it from the vehicle. 4. Reverse this procedure to
reinstall the seat. Make sure the seat tabs at the front edge of the seat slide under the seat retainer bar.
5. Press down firmly at the rear of the seat to engage the rear latch.
Front Seat Retainer
Seat Latch
31
FEATURES AND CONTROLS Passenger Hand Hold Always adjust the hand hold to a comfortable position for your passenger before operating. Make sure the adjustment pin and retainer are securely installed after making adjustments. 1. Remove the retainer from the end of the adjustment pin. 2. Remove the pin from the post. 3. Slide the post inward or outward to the desired position. 4. Reinstall the pin through the post mounting hole, adapter bushing
hole, both post adjustment holes and lastly through the remaining bushing hole and post mounting hole.
5. Reinstall the retainer to the pin.
Adjustment
Position Holes
Post Mounting Holes
Adjustment Pin
Pin Retainer
Adapter Bushing
32
FEATURES AND CONTROLS Hood Remove the hood to access the radiator pressure cap and coolant overflow bottle. 1. Turn the hood fasteners 1/4 turn. 2. Grasp the upper hood edge and pull upward to disengage the
fasteners. 3. Pivot the hood forward and lift upward to disengage the lower hood
hooks. 4. Lift the hood away from the vehicle.
Hood Fasteners
Pressure Cap
Overflow Bottle
33
FEATURES AND CONTROLS Fuel Cap The fuel tank filler cap is located on the right-hand side of the vehicle near the passenger seat. 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.
Service Access Panels Engine Access Panel The engine access panel is located behind the seats on the frame of the vehicle. Remove the seats and remove the access panel to reach serviceable engine components.
Cargo Box Access Panel The cargo box access panel is located on the floor of the cargo box. Remove the panel to access the engine oil fill cap, spark plugs and air filter.
Fuel Cap
34
FEATURES AND CONTROLS Cab Doors This vehicle is equipped with cab doors. Riding in this vehicle without closed and latched cab doors increases the risk of serious injury or death in the event of an accident or rollover. Always make sure all cab doors are closed and latched when riding in this vehicle. Always inspect doors and latches for wear and damage before each use of the vehicle. Promptly replace any worn or damaged parts with new parts available from your authorized POLARIS dealer.
Seat Belts This POLARIS vehicle is equipped with seat belts for all riders. Always make sure the seat belts are secured for the operator and all passengers before riding. The driver's seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 24 km/h if the seat belt is not secured.
3-Point Seat Belt To wear the 3-point seat belt properly, follow this procedure: 1. Pull the seat belt latch downward and across your chest toward the
buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.
2. Push the latch plate into the buckle until it clicks. Pull up on the strap to tighten.
3. Press the red release latch on the buckle to release the seat belt.
35
FEATURES AND CONTROLS Seat Belts Seat Belt Inspection Inspect all seat belts for proper operation before each use of the vehicle. 1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's securely latched.
2. Push the red release latch in the middle of the buckle to make sure it releases freely.
3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly, have the seat belt system checked and/or replaced by an authorized POLARIS dealer.
4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents. Rinse the entire length of the belt webbing. Use a garden hose to flush out the retractor and latch housings regularly.
Retractor Housing
Latch Housings
36
FEATURES AND CONTROLS Gear Selector P: Park R: Reverse N: Neutral L: Low Gear H: High Gear To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving. Tip: Maintaining shift linkage
adjustment is important to assure proper transmission function. See your dealer if you experience any shifting problems.
NOTICE: Do not attempt to shift the transmission while the vehicle is moving or damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.
Using Low Range Always shift into low gear for any of the following conditions. Operating in rough terrain or over obstacles Loading the vehicle onto a trailer Towing heavy loads
Gear Selector
37
FEATURES AND CONTROLS Brake Pedal Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.
Throttle Pedal Push the pedal 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. Tip: If the throttle pedal and brake pedal are applied simultaneously, engine
power may be limited.
Throttle Pedal
Brake Pedal
38
FEATURES AND CONTROLS Park Brake Lever Always apply the service brakes before engaging or releasing the park brake. 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, engine speed is limited. If the accelerator is applied, this limiting feature prevents operation, which protects the park brake pads from excessive wear. Tip: This feature will not operate properly if the park brake connector or switch
(under the hood) malfunctions or becomes disconnected, or if the switch has moved. Check for disconnection, then see your dealer promptly if this feature fails to operate properly.
1. To set the park brake, apply the brakes.
2. Pull the park brake lever upward as far as possible.
3. To release the park brake, apply the brakes. Press the park brake release inward and move the lever downward as far as possible.
Park Brake Lever
Park Brake Release
39
FEATURES AND CONTROLS Rollover Protective Structure (ROPS) The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way. No device can assure occupant protection in the event of a rollover. When used with seat belts and cab nets or doors, the ROPS helps prevent occupants from being ejected from the vehicle. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover. WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle rollover.
ROPS Label (on ROPS or on
passenger hip bar)
40
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. The switch has two positions, AWD (4x4) and 2WD (2x4). The switch on models equipped with a lockable differential has a third position for unlocking the differential. When unlocked, only one rear wheel is a drive wheel. See page 41. When the switch is on 2X4, the vehicle is in two-wheel drive at all times. When the switch is on AWD, the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on. When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.
Engaging AWD The AWD switch may be turned on or off while the vehicle is moving. 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 demand drive unit is moving, it will not disengage until the rear wheels regain traction. Engage the AWD switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to AWD. NOTICE: Switching to AWD while the rear wheels are spinning or slipping may
cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.
AWD
2WD
AWD
Differential Lock (2WD)
Differential Unlock (1WD)
AWD Switch (models with a
lockable differential)
AWD Switch
41
FEATURES AND CONTROLS All Wheel Drive (AWD) System Disengaging AWD Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving, they will not release until the rear wheels regain traction. In some situations, the front gearcase may remain locked after turning the AWD switch off. If this occurs, you may notice increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gearcase. 1. Stop the vehicle. 2. Operate in reverse for at least 3 m (10 feet). 3. Stop completely. 4. Shift into low gear and drive forward. 5. If the front gearcase remains locked after following these
instructions, see your dealer for service.
Locking/Unlocking the Differential (if equipped) NOTICE: Damage to the differential can
occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential.
Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) to lock the differential and operate in rear wheel drive. Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently. This mode of operation is well suited to turf driving or whenever aggressive traction is not required.
42
FEATURES AND CONTROLS Instrument Cluster NOTICE: High water pressure may damage components. Wash the vehicle by
hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
Speedometer The speedometer displays vehicle speed in either kilometers per hour (km/h) or miles per hour (MPH) . See page 46.
Mode Button Use the MODE button to toggle through mode options. See page 46 for operation of the modes.
Rider Information Center
Speedometer Indicator Lamps
MODE Button
43
FEATURES AND CONTROLS Instrument Cluster Indicator Lamps
Lamp Indicates Condition
Vehicle Speed
When standard mode is selected, speed displays in miles per hour.
When metric mode is selected, speed displays in kilometers per hour.
Over Temperature
This lamp illuminates to indicate an overheated engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.
EPS Warning (if equipped)
This indicator illuminates briefly when the key is turned to the ON position. If the light remains on, the EPS system is inoperative. See your authorized POLARIS dealer for service.
Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is set to high beam.
Helmet/Seat Belt
The lamp is a reminder to the operator to ensure all riders are wearing helmets and seat belts before operating. The driver's seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 24 km/h (15 MPH) if the seat belt is not secured.
Check Engine This indicator appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result. See your dealer.
Direction Indicators
A direction indicator flashes when a turn signal is active. Both indicators flash when the hazard signal is active.
44
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis. The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 47.
1. Gear Indicator - This indicator displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park -- = Gear Signal Error (or shifter between gears)
1
2
6 5
4
7
3
8
45
FEATURES AND CONTROLS Instrument Cluster Rider Information Center 2. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the fuel sensor circuit. See your dealer.
3. Information Display Area - This area displays odometer, trip meter, engine hour meter and programmable service hour interval.
4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.
5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 47 for resetting instructions.
6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 47 for resetting instructions.
7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is on 4X4).
8. Turf Mode Indicator - This indicator illuminates when the operator unlocks the differential. See page 41.
46
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Use the MODE button to toggle through the information area options.
Display Units (Standard/Metric) The display can be changed to show either standard or metric units of measurement for each of the following settings. Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key
on. The gauge display the mode that was displayed prior to setting the units.
1. Turn the key to the OFF position. 2. Press and hold the MODE button while turning the key to the ON
position. 3. When the display flashes the distance setting, tap the MODE button
to advance to the desired setting. 4. Press and hold the MODE button to save the setting and advance to
the next display option. 5. Repeat the procedure to change remaining display settings.
Metric Display Standard Display Distance Kilometers Miles
Fuel Liters, Imperial Gallons U.S. Gallons
Temperature Celsius Fahrenheit
Time 24-Hour Clock 12-Hour Clock
MODE Button
47
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Clock Mode Tip: The clock must be reset any time the battery has been disconnected or dis-
charged.
1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
2. Press and hold the MODE button until the hour segment flashes. Release the button.
3. With the segment flashing, tap the MODE button to advance to the desired setting.
4. Press and hold the MODE button until the next segment flashes. Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.
6. Turn the key to the OFF position. Odometer Mode The odometer records and displays the distance traveled by the vehicle.
Trip Meter Mode The trip meter records the distance traveled by the vehicle if reset before each trip. To reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.
Hour Meter Mode This mode logs the total hours the engine has been in operation.
Engine Temperature Mode This mode displays current temperature of the coolant.
48
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Battery Voltage Mode This mode displays current system voltage level.
Tachometer Mode The engine RPM is displayed digitally. Tip: Small fluctuations in the RPM from day to day may be normal because of
changes in humidity, temperature and elevation.
Programmable Service Interval When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval. 1. Press the MODE button until remaining service hours display. 2. Press and hold the MODE button. 3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.
Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code). The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults. Inactive codes are stored in the history of the unit.
49
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine. If the CHECK ENGINE light illuminates, retrieve the error codes from the display. 1. If the error codes are not displayed, use the MODE button to toggle
until Ck ENG displays on the main line of the display. 2. Press and hold the MODE button to enter the diagnostics code
menu. 3. Record the three numbers displayed in the gear position, clock and
odometer displays. 4. Press the MODE button to advance to the next error code. 5. Press and hold the MODE button to exit the diagnostics code menu. 6. See an authorized POLARIS dealer for code details and diagnosis.
Suspect Parameter Number (SPN)Error Code
Number (0-9)
Failure Mode Indicator (FMI)
50
OPERATION
Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owners manual.
Vehicle Break-in Period The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. Clutch and drive belt break-in periods vary depending on operating conditions. See page 51. No single action on your part is as important as a proper break-in period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully. NOTICE: Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts and drive components. Do not operate at full throttle or high speeds during the first three hours of use.
Use of any oils other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS PS-4 oils for your 4-cycle engine.
Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 33. Always exercise
extreme caution whenever handling gasoline. 2. Check the oil level. See page 89. Add the recommended oil as
needed to maintain the oil level in the safe operating range. 3. Complete the New Operator Driving Procedures outlined on pages
56-57. 4. Avoid aggressive use of the brakes. See Brake System Break-in on
page 51. 5. Vary throttle positions. Do not operate at sustained idle. 6. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 52.
WARNING
51
OPERATION Vehicle Break-in Period Engine and Drivetrain Break-in 7. Carry only light loads. 8. During the break-in period, change both the oil and the filter at 25
hours or one month. 9. Check fluid levels of transmission and all gearcases after the first 25
hours of operation and every 100 hours thereafter.
Brake System Break-in Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.
PVT Break-in (Clutches/Belt) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. If a belt fails, always clean any debris from the duct and from the engine compartment.
Standard Break-In Drive at slower speeds for the first 80 km (50 miles) of operation. Carry only light loads. Avoid aggressive acceleration, high-speed operation and prolonged operation at a specific RPM during this period.
Sand/Dune Break-In Drive in low gear for the first 8 km (5 miles) of operation. Avoid prolonged low speed operation at high throttle. Avoid aggressive acceleration, high-speed operation and prolonged operation at a specific RPM during this period.
52
OPERATION Pre-Ride Inspection Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.
Item Remarks Page Brake system/pedal travel Ensure proper operation 37
110
Brake fluid Ensure proper level 112
Front suspension Inspect, lubricate if necessary 86
Rear suspension Inspect, lubricate if necessary 86
Steering Ensure free operation 119
Tires Inspect condition and pressure 12 117
Wheels/fasteners Inspect, ensure fastener tightness 117
Frame nuts, bolts, fasteners Inspect, ensure tightness -
Fuel and oil Ensure proper levels 45 89
Coolant level Ensure proper level 101- 102
Coolant hoses Inspect for leaks -
Throttle Ensure proper operation -
Indicator lights/switches Ensure proper operation 26-27
Engine intake pre-filter Inspect, clean 106
PVT intake pre-filter Inspect, clean 106
Headlights Check operation -
Turn Signals Ensure operation of all signal lamps 28
Mirrors Adjust for best side/rear vision 29
Horn Ensure operation 27
Brake light/taillight Check operation -
Seat Latches Push down on both seat backs to ensure the latches are secure
30
Seat Belts Check length of belt for damage, check latches for proper operation
34
Cab Doors Check doors and latches for wear or damage.
34
Riding gear Wear approved helmet, goggles, and protective clothing
8
53
OPERATION Safe Operation Practices 1. POLARIS strongly encourages you and any family members who
will be riding this vehicle to take a training course. Complete the New Operator Driving Procedures outlined on pages 56-57.
2. Do not allow anyone under 16 years of age or without a valid drivers license to operate this vehicle.
3. Never operate with a passenger under the age of 12. Never carry more one passenger in a 2-seat vehicle. Never allow a passenger to ride in the cargo box.
4. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area.
5. Never operate with accessories not approved by POLARIS for use on this vehicle.
6. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel during operation.
8. Never consume alcohol or drugs before or while operating this vehicle.
9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.
10. Never operate a damaged vehicle. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.
11. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your passengers, and your cargo, together with any other vehicles in your party.
12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
54
OPERATION Starting the Engine 1. Position the vehicle on a level surface outdoors or in a well-
ventilated area. 2. Sit in the drivers seat and fasten the seat belt. Always make sure all
cab doors are closed and latched when riding in this vehicle. 3. Place the transmission in PARK. 4. Apply the brakes. Do not press the throttle pedal while starting the
engine. 5. Turn the ignition key to the
START position. Engage the starter for a maximum of five seconds. Release the key when the engine starts. Turn the key to either LIGHTS ON or POSITION LIGHTS ON.
6. If the engine does not start within five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts.
7. Vary the engine RPM slightly with the throttle to aid in warm up until the engine idles smoothly.
NOTICE: Operating the vehicle immediately after starting could cause engine damage. Allow the engine to warm up for several minutes before operating the vehicle.
Stopping the Engine 1. Release the throttle pedal completely and brake to a complete stop. 2. Place the transmission in PARK. 3. Turn the engine off.
OFF START
LIGHTS ON POSITION
LIGHTS ON
55
OPERATION Braking 1. Release the throttle pedal completely. Tip: When the throttle pedal is released completely and engine speed slows to
near idle, the vehicle has no engine braking.
2. Press on the brake pedal evenly and firmly. 3. Practice starting and stopping (using the brakes) until youre
familiar with the controls.
Parking the Vehicle 1. Stop the vehicle on a level surface. 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.
2. Place the transmission in PARK. 3. Engage the park brake. 4. Turn the engine off. 5. Remove the ignition key to prevent unauthorized use.
56
OPERATION New Operator Driving Procedures
1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle.
2. Take a training course. 3. Perform the pre-ride inspection. See page 52. 4. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle. 5. Do not carry cargo during this period. 6. Select an open area that allows room to familiarize yourself with
vehicle operation and handling. 7. The driver and all passengers must wear helmet, eye protection,
gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times.
8. Always make sure all cab doors are closed and latched when riding in this vehicle.
9. Sit in the driver's seat and fasten the seat belt. 10. Place the transmission in PARK. 11. Start the engine.
57
OPERATION New Operator Driving Procedures 12. Apply the brakes and shift into low gear. 13. Check your surroundings and determine your path of travel. 14. Release the park brake. 15. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving. 16. Drive slowly at first. On level surfaces, practice starting, stopping,
turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.
17. Increase speed only after mastering all maneuvers at a slow speed. 18. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions: Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Operate at speeds appropriate for your skills, the conditions and
the terrain. DO NOT do power slides, donuts, jumps or other driving
stunts.
58
OPERATION Driving with Passengers 1. Complete the New
Operator Driving Procedures outlined on pages 56-57.
2. Perform the pre-ride inspection. See page 52.
3. Do not carry more than one passenger in a 2-seat vehicle. Additional passengers can affect the operators ability to steer and operate the controls.
4. Make sure all passengers are at least 12 years of age. All riders must be able to sit with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if driving) or on a passenger hand hold.
5. The driver and all passengers must wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. See page 8.
6. Always make sure all cab doors are closed and latched when riding in this vehicle.
7. Allow a passenger to ride only in a passenger seat. 8. 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.
9. Vehicle handling may change with passengers and/or cargo on board. Allow more time and distance for braking.
10. Always follow all operating guidelines as outlined on safety labels and in this manual.
59
OPERATION Driving on Slippery Surfaces When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions: 1. Slow down before entering slippery areas. 2. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids. 3. Engage all-wheel drive before wheels begin to lose traction. NOTICE: Severe damage to the drive train may occur if the AWD is engaged
while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.
4. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.
Sideways skid
Turn in direction of
skid
60
OPERATION Driving Uphill Whenever traveling uphill, follow these precautions: 1. Always check the terrain carefully before ascending a hill. Never
drive on hills with excessively slippery or loose surfaces. 2. Avoid excessively steep hills. If ascending a steeper grade is
unavoidable, engage all-wheel drive before ascending. 3. Drive straight uphill. 4. Proceed at a steady rate of speed and throttle opening. Never open
the throttle suddenly. 5. Avoid unnecessary changes in speed or direction. 6. Never go over the crest of a hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the hill.
7. If the vehicle stalls while climbing a hill, apply the brakes. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.
61
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary. If crossing a hill is unavoidable, follow these precautions: 1. Engage all-wheel drive. 2. Drive slowly and use extreme caution. 3. If the vehicle begins to roll over, or if it feels as if it may roll over,
immediately turn downhill. 4. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide. 5. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.
Driving Downhill Whenever descending a hill, follow these precautions: 1. Avoid excessively steep
hills. 2. Slow down. Never
travel down a hill at high speed.
3. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces.
4. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral.
5. Avoid traveling down a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill.
6. Apply the brakes lightly to aid in slowing.
62
OPERATION Driving Through Water Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water: 1. Determine water depth and
current before entering water.
2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. Never operate in water that exceeds the maximum recommended depth.
WARNING! The large tires on your vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of traction, loss of control, rollover or accident.
3. Wet brakes may have reduced stopping ability. After leaving water, test the brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads. Avoid applying brake and throttle at the same time.
NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart. See page 81. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil, and all grease fittings.
If your vehicle becomes immersed or is operated in water that exceeds the floor level, take it to your dealer for service before starting the engine. If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 122, and take the vehicle to your dealer at the first opportunity.
Floor Level
63
OPERATION Driving Over Obstacles
Follow these precautions when operating over obstacles: 1. Always check for obstacles before operating in a new area. 2. Look ahead and learn to read the terrain. Be constantly alert for
hazards such as logs, rocks and low hanging branches. 3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible. 4. Avoid operating over large obstacles such as large rocks and fallen
trees. If unavoidable, use extreme caution and operate slowly. 5. Always have all passengers dismount and move away from the
vehicle before operating over an obstacle that could cause a rollover.
64
OPERATION Driving in Reverse
Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. 2. Apply the throttle lightly. Never open the throttle suddenly. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid making sharp turns.
65
OPERATION Parking on an Incline
A rolling vehicle can result in serious injury. Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions: 1. Apply the brakes. 2. Place the transmission in PARK. 3. Turn the engine off. 4. Block the rear wheels on the downhill side.
66
OPERATION Hauling Cargo
Overloading the vehicle or carrying cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never exceed the stated load capacity for this vehicle. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, accessories and loads in the rack or box. The combined weight of these items must not exceed the maximum weight capacity. Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Always operate the vehicle with extreme care when hauling cargo. Slow down and drive in the lowest gear available. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. \ HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill. USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing a rollover. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 16 km/h (10 MPH) while cornering or while ascending or descending a hill. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box. A passenger must always be seated in a passenger seat with seat belt secured.
WARNING
67
OPERATION Hauling Cargo Your POLARIS vehicle has been designed to carry a specific capacity. Reduce speed and allow a greater distance for braking when carrying cargo. Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box. Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. See page 132.
Belt Life To extend belt life, use low gear when hauling or towing heavy cargo.
68
OPERATION Towing
Towing improperly can alter vehicle handling and may cause loss of control or brake instability.
The tow loop on the rear of the vehicle is provided for recovery use ONLY. Tow a vehicle ONLY of equal or lesser size and weight. When towing a disabled RZR vehicle, place the disabled vehicle's transmission in neutral. Do not operate the vehicle faster than 16 km/h (10 MPH) when towing.
WARNING
Tow Loop
69
WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term winch cable will be used for either unless noted otherwise.
Winch Safety Precautions 1. Read all sections of this manual. 2. Never use alcohol or drugs before or while operating the winch. 3. Never allow children under 16 years of age to operate the winch. 4. Always wear eye protection and heavy gloves when operating the
winch. 5. Always keep body, hair, clothing and jewelry clear of the winch
cable, fairlead and hook when operating winch. 6. Never attempt to jerk a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 78. 7. Always keep the area around the vehicle, winch, winch cable and
load clear of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
WARNING
70
WINCH GUIDE Winch Safety Precautions 10. Always apply your vehicles park brake and/or park mechanism to
hold the vehicle in place during winching. Use wheel chocks if needed.
11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicles centerline whenever possible.
12. If winching at an angle is unavoidable, follow these precautions: A. Look at the winch drum occasionally. Never let the winch cable stack
or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
B. If stacking occurs, stop winching. Follow step 15 on page 76 to feed and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winchs rated capacity.
15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the winch cable while winching a load.
17. Never let the winch cable run through your hands, even if wearing heavy gloves.
71
WINCH GUIDE Winch Safety Precautions 18. Never release the clutch on the winch when the winch cable is under
load. 19. Never use the winch for lifting or transporting people. 20. Never use the winch to hoist or suspend a vertical load. 21. Never immerse or submerse your winch in water. Take your winch
to your dealer for service if this occurs. 22. Always inspect your winch and winch cable before each use. 23. Never winch the hook fully into the winch. This can cause damage
to winch components. 24. Unplug the remote control from the vehicle when the winch is not in
use to prevent inadvertent activation and use by unauthorized persons.
25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.
72
WINCH GUIDE Winch Operation Read the Winch Safety Precautions in the preceding pages before using your winch. Tip: Consider practicing the operation and use of your winch before you actually
need to use it in the field.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual. Each winching situation is unique.
Take your time to think through the winching you are about to do.
Proceed slowly and deliberately.
Never hurry or rush during winching.
Always pay attention to your surroundings.
You may need to change your winching strategy if it is not working.
Always remember that your winch is very powerful.
There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first meter (3 feet) of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or damaged cable.
2. Never operate a winch or a vehicle in need of repair or service. 3. Always apply your
vehicles park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.
WARNING
Hook Strap
73
WINCH GUIDE Winch Operation 4. Always use the hook strap when
handling the hook. WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY.
A. Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable.
Tip: A tow strap is NOT intended to stretch. A recovery strap is designed to stretch.
WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 78.
B. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
D. If freeing a stuck vehicle by attaching to a tree, use an item such as a tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees.
E. Before operating the winch, be sure that the safety latch on the winch cable hook is fully seated when the load is attached.
F. Never operate your winch with a damaged hook or latch. Always replace damaged parts before using the winch.
NO YES
NOYES
74
WINCH GUIDE Winch Operation 5. Never remove the hook strap from the hook. 6. Release the winch clutch and pull out the winch cable. 7. Pulling out as much cable as possible maximizes the winchs pulling
capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
8. Read and adhere to the following information for winch damping to ensure safe winch use. A. In order to absorb energy that could be released by a winch cable
failure, always place a damper on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
B. Lay the damper on top of the mid-point of the winch cable length that is spooled out.
C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
75
WINCH GUIDE Winch Operation 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 78. For your safety, always follow these guidelines when winching a vehicle free: A. Release the winch clutch and spool out the necessary length of winch
cable. B. Align the winch cable as close as possible to the winching vehicles
centerline. C. Attach the winch cable hook to the anchor point or the stuck vehicles
frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the
direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle and winch together to free
the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself
without the help of the winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.
13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicles engine run while operating the winch to prevent the battery from running low if winching for long periods.
76
WINCH GUIDE Winch Operation 14. The winch motor may become hot during winch use. If you winch
for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task. A. Release the clutch on the winch. B. Feed out the winch cable that is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 45 kg (100
lbs.) of tension using the hook strap. E. Slowly winch the cable in while your assistant moves the end of the
winch cable back and forth horizontally to evenly distribute the winch cable on the drum.
F. Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable.
77
WINCH GUIDE Winch Cable Care For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer. WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.
1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A. A kinked winch cable made of
wire rope is shown at right. Even after being straightened out, this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.
B. A kinked winch cable made of wire rope that has been straightened out is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.
C. A winch cable made of synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.
D. 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.
A
B
C
78
WINCH GUIDE Shock Loading WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or shock loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables. 1. Never attempt to jerk a load with the winch. For example, never
take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It gener- ates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.
WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (jogging). This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.
4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic bungie cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.
79
WINCH GUIDE Winch Maintenance and Service Safety WARNING! Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your winch.
3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.
WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.
80
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.
Spark Arrester Your POLARIS vehicle has a spark arrester that was designed for on- road and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.
Exhaust Emission Control System Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
Electromagnetic Interference This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC. 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.
European Vibration and Noise The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on many factors, including: Instrument and calibration uncertainty Variations in the machine such as wear of components Variation of machine operators such as experience or physique Ability of the worker to reproduce typical work during measurements Environmental factors such as ambient noise or temperature
81
MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance will help keep your vehicle in the safest, most reliable condition. Inspection, adjustment and lubrication of important components are explained in the periodic maintenance chart. Inspect, clean, lubricate, adjust and replace parts as necessary. When inspection reveals the need for replacement parts, use genuine POLARIS parts available from your POLARIS dealer. Record maintenance and service in the Maintenance Log beginning on page 143. Service and adjustments are important for proper vehicle operation. If you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations. Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.
Severe Use Definition Frequent immersion in mud, water or sand Racing or race-style high RPM use Prolonged low speed, heavy load operation Extended idle Frequent short trip operation in cold weather (engine frequently does
not operate long enough to reach full operating temperature) 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 or see your dealer.
82
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key Perform these operations more often for vehicles subjected to severe use. E Emission-related service D Have an authorized POLARIS dealer perform these services. WARNING! Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
83
MAINTENANCE Periodic Maintenance Chart Perform all services at whichever maintenance interval is reached first.
Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval (whichever comes first)
Remarks
Hours Calendar km (Miles)
Steering - Pre-Ride - Make adjustments as need ed. See Pre-Ride Checklist on page 52.
Front suspension - Pre-Ride - Rear suspension - Pre-Ride - Tires - Pre-Ride - Brake fluid level - Pre-Ride - Brake pedal travel Brake system - Pre-Ride - Wheels/fasteners - Pre-Ride - Frame fasteners - Pre-Ride - Engine oil level - Pre-Ride -
E Engine intake pre-filter - Daily - Inspect; clean often PVT intake pre-filter - Daily - Inspect; clean often Coolant - Daily - Check coolant level
Power steering unit (if equipped)
- Daily - Inspect daily; clean often
Headlight/taillight - Daily - Check operation Spark arrester - Daily - Clean daily when driving in
mud and water; replace a cracked or damaged arrester before operating
Fuel System 25 H Monthly - Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion
Engine oil change (break-in)
25 H 1 M - Perform a break-in oil and filter change at one month
Front gearcase (demand drive) fluid
25 H 1 M - Perform a break-in oil level check
Transmission (main gearcase) oil
25 H 1 M - Perform a break-in oil level check
D
Brake pad wear 10 H Monthly 160 (100) Inspect periodically
Battery 25 H Monthly 400 (250) Check terminals; clean; test
E
Engine breather filter (if equipped)
25 H Monthly 250 (150) Inspect; replace if necessary
E
Air filter 25 H - 800 (500) Replace filter
84
MAINTENANCE Periodic Maintenance Chart
Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval (whichever comes first)
Remarks
Hours Calendar km (Miles)
General lubrication 50 H 3 M 800 (500) Lubricate all fittings, pivots, cables, etc.
D E
Throttle pedal 50 H 6 M 800 (500) Inspect for free movement; replace pedal as needed
E Throttle body air intake ducts/flange
50 H 6 M 500 (300) Inspect duct for proper sealing/air leaks
Shift Linkage 50 H 6 M 800 (500) Inspect, adjust
Front Suspension 50 H 6 M 800 (500) Lubricate
Rear Suspension 50 H 6 M 800 (500) Lubricate
Cooling system (if applicable)
50 H 6 M 800 (500) Inspect coolant strength seasonally; pressure test system yearly
Engine oil change 50 H 6 M 1600 (1000) Perform a break-in oil change at one month
Oil filter change 50 H 6 M 1600 (1000) Replace with oil change
Oil lines, fasteners 50 H 6 M 1600 (1000) Inspect for leaks and loose fittings
Front gearcase (demand drive) fluid
100 H 12 M 1600 (1000) Change fluid
Transmission (main gearcase) oil
100 H 12 M 1600 (1000) Change fluid
D E
Fuel system 100 H 12 M 1600 (1000) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
E
Spark plugs 100 H 12 M 1600 (1000) Inspect; replace as needed, torque to specification
85
MAINTENANCE Periodic Maintenance Chart
Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval (whichever comes first)
Remarks
Hours Calendar km (Miles)
Radiator 100 H 12 M 1600 (1000) Inspect; clean external surfaces
Cooling Hoses 100 H 12 M 1600 (1000) Inspect for leaks
Engine mounts 100 H 12 M 1600 (1000) Inspect
Exhaust muffler/ pipe
100 H 12 M 1600 (1000) Inspect
Wiring 100 H 12 M 1600 (1000) Inspect for wear, routing, security; apply dielectric grease to connectors subjected to water, mud, etc.
D Clutches (drive and driven)
100 H 12 M 1600 (1000) Inspect; clean; replace worn parts
Drive belt 100 H 12 M 1600 (1000) Inspect; replace as needed
Shock Seals 100 H - - Inspect shock seals
D
Shocks - 12 M 2400 (1500) See your dealer for oil change/seal inspection.
D Front wheel bearings
100 H 12 M 1600 (1000) Inspect; replace as needed
D Brake fluid 200 H 24 M 3200 (2000) Change every two years
Spark arrester - 24 M 3200 (2000) Clean daily when driving in mud and water; replace a cracked or damaged arrester before operating
Valve lash 200 H - 3200 (2000) Check; adjust as needed
E
Spark plugs 500 H 36 M 8000 (5000) Replace, torque to specification
Coolant - 60 M - Replace coolant
D Toe adjustment - Inspect periodically; adjust when parts are replaced
Headlight aim - Adjust as needed
86
MAINTENANCE Lubrication Recommendations Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.
Item Lube Method Engine Oil PS-4 5W-50 4-Cycle Oil and
PS-4 Extreme Duty 10W-50 4-Cycle Oil
See page 88.
Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines. See page 112.
Transmission Oil (Main Gearcase)
AGL Gearcase Lubricant & Transmission Fluid
See page 92.
Front Gearcase Fluid (Demand Drive)
Demand Drive Fluid See page 94.
Prop Shaft U-Joint Grease Grease middle and rear fittings.
Front Control Arm Pivot Bushings
All Season Grease or grease conforming to NLGI No. 2
Grease 3 fittings on each side of the vehicle.
Stabilizer Bar Bushings All Season Grease or grease conforming to NLGI No. 2
Remove engine access panel and grease 2 fittings (one on each side of vehicle)
Middle Prop Shaft Grease Fitting
Rear Prop Shaft Grease Fitting
87
MAINTENANCE Lubrication Recommendations
Stabilizer Bar Bushings (one on each side of vehicle)
Front Control Arm Pivot Bushings
(3 per side)
Front Suspension (viewed from rear)
88
MAINTENANCE Engine Oil Oil Recommendations WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.
Oil may need to be changed more frequently if POLARIS oil is not used. Do not use automotive oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 134 for the part numbers of POLARIS products. NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or mix oil brands.
Ambient Temperature Range Recommended Oil -37 C to +38 C
(-35 F to +100 F) PS-4 5W-50 4-Cycle Oil
-18 C to +49 C (0 F to 120 F)
PS-4 Extreme Duty 10W-50 4-Cycle Oil
89
MAINTENANCE Engine Oil Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil.
Oil Check Always check the oil when the engine is cold. If the engine is hot when the oil is checked, the level will appear to be overfull. Access the oil check dipstick through the right rear wheel well. Access the oil fill cap through the service access panel on the floor of the cargo box. 1. Position the vehicle on a
level surface. 2. Place the transmission in
PARK. 3. Remove the dipstick. Wipe
it dry with a clean cloth. 4. Reinstall the dipstick
completely. Remove the dipstick and check the oil level.
5. Remove the oil fill cap to add the recommended oil as needed. Maintain the oil level between the minimum and maximum marks on the dipstick. Do not overfill.
6. Reinstall the fill cap. Reinstall the dipstick.
Oil Check
Oil Fill
90
MAINTENANCE Engine Oil Oil and Filter Change Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil. Access the oil check dipstick through the right rear wheel well. Access the oil fill cap through the service access panel on the floor of the cargo box. The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole under the crankcase. 1. Position the vehicle on a level surface. Place the transmission in
PARK. 2. Clean the area around the crankcase drain plug. CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact skin.
3. Place a drain pan under the engine crankcase and remove the drain plug. Allow the oil to drain completely.
4. Using an oil filter wrench, turn the filter counter- clockwise to remove it.
5. Using a clean dry cloth, clean the filter sealing surface on the crankcase.
Oil Filter
91
MAINTENANCE Engine Oil Oil and Filter Change 6. Lubricate the o-ring on the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition. 7. Install the new filter and turn by hand until the filter gasket contacts
the sealing surface, then turn and additional 3/4 turn. 8. Reinstall the crankcase drain plug. Torque to 16 Nm. 9. Remove the oil fill cap and add 2.4 l (2.5 quarts) of recommended
oil. Reinstall the fill cap. 10. Remove the dipstick. Wipe it dry with a clean cloth. 11. Reinstall the dipstick completely. Remove the dipstick and check
the oil level. 12. Remove the oil fill cap to add the recommended oil as needed.
Maintain the oil level between the minimum and maximum marks on the dipstick. Do not overfill.
13. Reinstall the fill cap. 14. Reinstall the dipstick. 15. Dispose of used filter and oil properly.
92
MAINTENANCE Transmission (Main Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications.
Fluid Check The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.
1. Position the vehicle on a level surface. 2. Remove the fill plug. 3. Check the fluid level. 4. Add the recommended fluid to the bottom of the fill plug hole. Do
not overfill. 5. Reinstall the fill plug. Torque to specification.
Fill Plug
93
MAINTENANCE Transmission (Main Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. Access the drain plug through the drain hole in the skid plate. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean the drain plug. 5. Reinstall the drain plug. Torque to specification. 6. Add the recommended fluid to the bottom of the fill plug hole. Do
not overfill. 7. Reinstall the fill plug. Torque to specification. 8. Check for leaks. Discard used fluid properly.
Demand Drive Drain Plug
Transmission Drain Plug
94
MAINTENANCE Demand Drive Unit (Front Gearcase) Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications.
Fluid Check The fill plug is located on the bottom right side of the demand drive unit. Maintain the fluid level even with the bottom thread of the fill plug hole. 1. Position the vehicle on a
level surface. 2. Remove the fill plug. Check
the fluid level. 3. Add the recommended fluid
to the bottom thread of the fill plug hole.
4. Reinstall the fill plug. Torque to specification.
Fill Plug
95
MAINTENANCE Demand Drive Unit (Front Gearcase) Fluid Change The drain plug is located on the bottom of the gearcase. 1. Remove the fill plug. 2. Place a drain pan under the drain plug. 3. Remove the drain plug. Allow the fluid to drain completely. 4. Clean the drain plug. 5. Reinstall the drain plug. Torque to specification. 6. Add the recommended fluid to the bottom thread of the fill plug
hole. 7. Reinstall the fill plug. Torque to specification. 8. Check for leaks. Discard used fluid properly.
Demand Drive Drain Plug
Transmission Drain Plug
96
MAINTENANCE Gearcases Gearcase Specification Chart Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products.
Spark Plugs Spark Plug Gap/Torque
NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs. Refer to the specifications section beginning on page 132.
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. See page 97. CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.
Gearcase Lubricant Capacity Fill Plug Torque
Drain Plug/ Level Check Plug Torque
Transmission (Main Gearcase)
AGL Gearcase Lubricant &
Transmission Fluid
1.3 l (44 oz.)
Turf Models: 1.2 l (40.5 oz.)
14-19 Nm 14-19 Nm
Demand Drive Unit (Front Gearcase)
Demand Drive Fluid
250 ml (8.5 oz.) 11-14 Nm 11-14 Nm
Electrode Gap Spark Plug Torque 0.7-0.8 mm 10 Nm
97
MAINTENANCE Spark Plugs Spark Plug Removal and Replacement 1. Remove the cargo box access
panel. 2. Clean the area around the spark
plugs before removing the plugs.
3. Remove the spark plug caps. 4. Using the spark plug wrench
provided in the tool kit, remove the plugs by rotating them counter-clockwise.
5. Reverse the procedure for spark plug installation. Torque to specification. See page 96.
Spark Plug Condition Normal Plug The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. Tip: The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body adjust- ments.
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. Fouling may be caused by excessive oil or by frequent short trips, especially in cold weather.
Spark Plugs
98
MAINTENANCE Fuse/Relay Center If the engine stops or will not start, if the power steering stops working (if equipped), 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/relay center is located under the drivers seat.
Label Value Function FAN 20A Circuit Breaker Fan EFI 10A Fuse EFI Relay, Injectors, Coil, ECM,
Chassis Relay Coil, Fan Relay Coil, Fuel Pump Relay Coil
SYS 10A Fuse Gauge, EFI Relay Coil, EPS Relay Coil, Key Switch, Gauge, EPS Wake Up, Speed Sensor, Hazard Flasher
TERM 10A Fuse Under Hood Terminal Block, Interior LED
EPS 20A Fuse Power Steering LIGHTS 10A Fuse Forward Indicator lights, Turn
Signals, Taillights, Dash lighting DRIVE 10A Fuse AWD Coil, Turf Relay ACCESSORY 10A Fuse 12V Receptacle KEY 10A Fuse Headlights, Start Relay Coil
99
MAINTENANCE Cooling System The engine coolant level is maintained by the recovery system. The recovery system components are the overflow bottle, radiator vent fitting, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiator. Tip: Some coolant level drop on new vehicles is normal as the system is purging
itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the overflow bottle.
Adding or Changing Coolant POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 134 for the part numbers of POLARIS products. To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added. See page 101 for changing procedure. Any time the cooling system has been drained for maintenance or repair, replace the coolant with fresh Antifreeze 50/50 Premix.
100
MAINTENANCE Cooling System Radiator and Cooling Fan Always check and clean the screen and radiator fins at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage. NOTICE: Washing the vehicle with a high-pressure hose could damage the
radiator fins and impair the radiator's effectiveness. Using a high- pressure system is not recommended.
101
MAINTENANCE Cooling System Radiator Coolant Level/Changing Coolant This procedure is required only if the cooling system has been drained for maintenance and/or repair. If the overflow bottle has run dry, the level in the radiator should also be inspected. CAUTION! Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot. Always allow the engine to cool before removing the pressure cap.
1. Remove the hood. See page 32.
2. Slowly remove the radiator pressure cap.
3. View the coolant level through the opening.
4. Use a funnel and slowly add coolant as needed.
5. Before reinstalling the pres- sure cap, bleed the system of trapped air. Remove the engine access panel behind the seats and use a flat-blade screwdriver to turn the bleed screw slightly, allowing the air to escape. Slowly add additional coolant to the radiator until air no longer escapes and only coolant flows from the bleed hole, then tighten the bleed screw.
6. Reinstall the pressure cap. Tip: Use of a non-standard pressure
cap will not allow the recovery system to function properly. See your dealer for the correct replacement part.
Bleed Screw
Pressure Cap
Overflow Bottle
102
MAINTENANCE Cooling System Overflow Bottle Coolant Level Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). If the overflow bottle has run dry, the level in the radiator should also be inspected. 1. Position the vehicle on a
level surface. 2. Remove the hood. See page
32. 3. View the coolant level in the
overflow bottle. 4. Remove the cap and use a
funnel to add coolant as needed to maintain the level between the two marks.
5. Reinstall the cap. Tip: If coolant must be added often,
or if the overflow bottle runs completely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.
Pressure Cap
Overflow Bottle
103
MAINTENANCE POLARIS Variable Transmission (PVT) System
Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the PVT system. Doing so may reduce its strength so that a failure may occur at a high speed. The PVT system has been precision balanced. Any modification will cause the system to be out of balance, creating vibration and additional loads on components.
The PVT system rotates at high speeds, creating large amounts of force on clutch components. As the owner, you have the following responsibilities for your own safety and the safety of others:
Always follow all recommended maintenance procedures. Always look for and remove debris inside and around the clutch and vent system when replacing the belt.
See your dealer as recommended in the owners manual and on safety labels.
This PVT system is intended for use on POLARIS products only. Do not install it in any other product.
Always make sure the PVT housing is securely in place during operation.
WARNING
104
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal If a belt fails, always clean any debris from the duct and from the clutch and engine compartments when replacing the belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss of control and severe injury or death.
1. Allow hot components to cool before performing this procedure.
2. Remove the engine access panel and thoroughly clean all debris from the aluminum debris basket and from the engine compartment.
3. Remove the clutch cover screws and open the clutch cover. (It does not have to be removed from the vehicle.) Remove all debris wrapped in and around the PVT system.
Tip: Use the shock/clutch tool from the tool kit to slightly open the sheaves to aid in debris removal and belt installation.
(Continued on next page)
Debris Basket
Remove ALL Debris
Insert hooked end of tool. Apply force to opposite end of tool to spread sheaves.
105
MAINTENANCE POLARIS Variable Transmission (PVT) System Belt Replacement/Debris Removal 4. Remove all debris from the
entire clutch air duct passage. 5. Check for signs of damage to
seals on the transmission and engine. See your dealer promptly for service if any seals appear to be damaged.
Tip: Belt slip is responsible for creating excessive heat that destroys belts, wears clutch components and causes outer clutch covers to fail. Switch to low range while operating at slower speeds to extend the life of the PVT components (belt, cover, etc.).
PVT Drying There may be some instances when water is accidently ingested into the PVT system. Use the following instructions to dry it out before operating. 1. Remove the clutch cover drain plug. 2. Allow the water to drain. Reinstall the drain plug. 3. Place the transmission in PARK. Apply the brakes. 4. Start the engine. 5. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for more than 10 seconds.
6. Allow the engine RPM to settle to idle speed. Apply the brakes. Shift the transmission to the lowest available range.
7. Test for belt slippage. If the belt slips, repeat the process. 8. Take the vehicle to your dealer for service as soon as possible.
Clutch Air Duct
106
MAINTENANCE Filter Systems Intake Pre-Filters The engine intake pre-filter is located on the right side of the vehicle. The clutch air intake is located on the left side of the vehicle. Inspect the engine pre-filter before each use of the vehicle to ensure adequate air flow. If necessary, remove the pre-filter and clean with soapy water. Dry with low pressure compressed air. Periodically inspect the clutch (PVT) air intake for debris and clean as needed to ensure adequate air flow. Tip: When washing the vehicle, always avoid spraying water directly toward the
PVT intake duct. See page 127 for recommended washing procedures.
PVT Intake Pre-Filter
Engine Intake Pre-Filter
107
MAINTENANCE Filter Systems Air Filter Always change the air filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Remove the cargo box access
panel. 2. Clean all dirt and debris from
the air box area. 3. Unlatch the four (4) air box
cover clips and carefully remove the air box cover.
4. Inspect the air filter and air box for dirt, debris or water.
5. To remove the filter, slide the filter toward the passenger's side of the vehicle.
6. With the filter removed, clean the intake tube and air box thoroughly. Wipe well with a clean, dry cloth.
NOTICE: Dirt or debris in the intake tube could result in severe engine damage. Always clean all dirt and debris from the intake tube before installing the filter.
7. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to clean the air filter.
NOTICE: Use of a non-POLARIS-approved air filter may cause engine damage. Always use a POLARIS-approved replacement filter. Please see your POLARIS dealer.
8. Make sure that there are no gaps between the filter, the filter ring and the stop on the intake tube.
9. Reinstall the air box cover and ensure the alignment tabs are properly positioned.
10. Secure the four (4) cover clips. 11. Reinstall the cargo box access panel.
Air Filter
Cover Clips
108
MAINTENANCE Spark Arrester
Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death.
Do not perform clean-out immediately after the engine has been run, as the exhaust system becomes very hot. Serious burns could result from contact with the exhaust components. Allow components to cool sufficiently before proceeding.
Wear eye protection and gloves.
Never operate without the spark arrester.
Never run the engine in an enclosed area. Exhaust contains poisonous carbon monoxide gas that can cause loss of consciousness or death in a very short time.
WARNING
109
MAINTENANCE Spark Arrester Periodically clean the spark arrester to remove accumulated carbon. Clean daily when driving in mud and water. Replace a cracked or damaged arrester before operating. 1. Remove the arrester retaining bolt and nut. 2. Remove the arrester from the end of the muffler. 3. Use a non-synthetic brush to clean the arrester screen. A synthetic
brush may melt if components are warm. If necessary, blow debris from the screen with compressed air.
4. Inspect the screen for wear and damage. Replace a worn or damaged screen.
5. Reinstall the arrester. Torque bolt to 12-15 Nm.
Arrester Screen
Bolt
Muffler
Nut
110
MAINTENANCE Brakes The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. See page 37. Always check brake pedal travel and the brake fluid reservoir level before each use of the vehicle. When applied, the brake pedal should feel firm. Any sponginess would indicate a possible fluid leak or low brake fluid level, which must be corrected before riding. See page 112 for brake fluid information. If you discover any irregularities in brake system operation, including excessive pedal travel, contact your dealer for proper diagnosis and repairs. WARNING! Operating the vehicle with a spongy brake pedal can result in loss of braking, which could cause an accident resulting in severe injury or death. Never operate the vehicle with a spongy-feeling brake pedal.
111
MAINTENANCE Brakes Brake Inspection 1. Check the brake system for
fluid leaks. 2. Check the brake pedal for
excessive travel or a spongy feel.
3. Check the friction pads for wear, damage and looseness.
4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage. Clean any grease using an approved brake cleaner or alcohol.
WARNING! Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper.
5. Inspect the brake disc spline and pad wear surface for excessive wear. Change pads when worn to 0.762 mm.
0.762 mm
112
MAINTENANCE Brakes Brake Fluid Inspect the level of the brake fluid before each operation. If the fluid level is low add DOT 4 brake fluid only. See page 134 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury.
Change the brake fluid every two years and any time the fluid becomes contaminated, the fluid level is below the minimum, or if the type and brand of the fluid in the reservoir are unknown. Access the brake fluid reservoir through the left front wheel well. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. View the brake fluid level in the reservoir. The level should be
between the maximum and minimum level lines. 4. If the fluid level is lower than the lower level line, add brake fluid to
the upper line. 5. Apply the brake forcefully for a few seconds and check for fluid
leakage around the fittings.
Maximum Minimum
113
MAINTENANCE Suspension Settings Front/Rear Spring Preload The factory setting is appropriate for nearly all riding conditions. If desired, the suspension may be adjusted to maintain vehicle clearance height when carrying loads.
Factory Preload Settings RZR XP Front 42.86 cm (16.875 inches)
Rear 58 cm (22.825 inches)
HARD SOFT
Front Shock Preload Measurement
Rear Shock Preload Measurement
114
MAINTENANCE Suspension Settings Front/Rear Spring Preload Walker Evans Shock Preload Adjustment Follow these guidelines if you make adjustments to this suspension. Always return the suspension to the factory setting after the load is removed
from the vehicle. The increased suspension height will negatively impact vehi- cle stability when operating without a load.
Always apply the same adjustment setting to all four wheels.
Do not increase the spring preload by more than 25.4 mm (one inch) over the factory setting.
115
MAINTENANCE Suspension Settings Front/Rear Spring Preload Walker Evans Shock Preload Adjustment 1. Use the shock/clutch tool from the tool kit to aid in making suspen-
sion adjustments. 2. Elevate the vehicle to allow the suspension to fully extend. 3. Turn the adjusting ring to the left (1) to increase preload for a stiffer
ride. Turn the adjusting ring to the right (2) to decrease preload for a softer ride.
WARNING! Uneven adjustment may cause poor handling of the vehicle, which could result in an accident. Always adjust both the left and right spring preloads equally or have your POLARIS dealer perform the adjustments.
HARD SOFT
Adjusting Ring
Front Rear
Adjusting Ring
21
116
MAINTENANCE Suspension Settings Front/Rear Shock Compression The compression damping clicker knob is located at the top of the shock reservoir. When the knob is turned clockwise until it stops, the damping is in the fully closed position. When turned counter-clockwise until it stops, the damping is in the fully open position. 1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression
damping.
Walker Evans Shocks Setting Compression Damping Softest 16 clicks from closed Factory Front: 5-7 clicks from full counter-clockwise position
Rear: 5-7 clicks from full counter-clockwise position Firmest 1 click from closed
HARD SOFT
Front
Rear
Increase Decrease
Decrease
Increase
117
MAINTENANCE Tires
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 or less. Improper tire inflation or the use of non-standard size or type of tires may adversely affect vehicle handling, which could result in vehicle damage or personal injury. Always maintain proper tire pressure. Always use POLARIS- approved size and type of tires for this vehicle when replacing tires.
Tire Tread Depth Always replace tires when tread depth is worn to 3 mm or less.
Axle and Wheel Nut Torque Specifications Inspect the following items occasionally for tightness, and if they've been loosened for maintenance service. Do not lubricate the stud or the lug nut.
Lug Nut (Aluminum Wheels)
Front and Rear 146.4 Nm
Hub Retaining Nut Front and Rear 149 Nm
WARNING
3 mm
118
MAINTENANCE Tires Wheel Removal 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the
frame. 5. Remove the wheel lug nuts. Remove the wheel.
Wheel Installation 1. Place the transmission
in PARK. 2. Place the wheel in the
correct position on the wheel hub. Be sure the valve stem is toward the outside and rotation arrows on the tire point toward forward rotation.
WARNING! Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your POLARIS dealer.
3. Attach the wheel nuts and washers and finger tighten.
4. Carefully lower the vehicle to the ground. 5. Torque the wheel nuts to specification. See page 117.
Valve Stem
Right Rear Wheel (type varies by model)
119
MAINTENANCE Steering Wheel Inspection Check the steering wheel for specified freeplay and smooth operation at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. 1. Position the vehicle on level ground. 2. Lightly turn the steering wheel left and right. 3. There should be 20-25 mm of freeplay. 4. If there is excessive freeplay or strange noises, or if the steering
feels rough or catchy, have the steering system inspected by an authorized POLARIS dealer.
120
MAINTENANCE Lights Headlight and taillight lenses become dirty during normal operation. Clean all lights frequently to ensure a clear field of vision as well as visibility to other vehicles. Tip: If an LED headlamp has moisture or fogging inside, disconnect the wiring
harness from the headlamp(s) for a few days to allow the moisture to clear out.
Taillight/Brake Light/Turn Signal Lamp Replacement The taillight assembly is not serviceable. If the taillight or brake light fails to operate properly, replace the entire taillight assembly.
Headlight Replacement If a headlight becomes damaged or inoperable, the entire headlight assembly must be replaced. 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.
Front Turn Signal Lamp Replacement If a front turn signal light becomes inoperable, the lamps cannot be replaced. Replace the entire signal lamp assembly.
121
MAINTENANCE Lights Headlight Beam Adjustment The headlight beam can be adjusted slightly upward or downward and to the left or right.
1. Position the vehicle on a level surface. The headlight should be approximately 7.6 m (25 ft.) from a wall.
2. Place the transmission in PARK. 3. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height. 4. Apply the brakes. Start
the engine. Turn the headlights to high beam.
5. Include the weight of a rider on the seat while performing this step. Observe the headlight aim. As a starting point, the most intense part of the headlight beam should be 5 cm (2 inches) below the mark on the wall. Adjust to operator preference.
6. Tighten or loosen the three (3) headlight screws on the rear of the headlight to adjust the beam upward or downward or to the left or right.
7.6 m (25 ft.)
XX 5 cm (2 in.)
Adjustment Screws
122
MAINTENANCE Vehicle Immersion NOTICE: If your vehicle becomes immersed, major engine damage can result
if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.
If its impossible to take your vehicle to a dealer before starting it, follow the steps outlined below. 1. Move the vehicle to dry land. 2. Check the air box. See page 107. If water is present, dry the air box
and replace the filter with a new filter. 3. Remove the fuse/relay center cover. See page 98. Allow any
moisture to dry, then reinstall the cover. 4. Dry the spark plug wells with a clean cloth, then remove the spark
plugs. 5. Turn the engine over several times. 6. Dry the spark plugs and reinstall them, or install new plugs. 7. Attempt to start the engine. If necessary, repeat the drying
procedure. 8. Take the vehicle to your dealer for service as soon as possible,
whether you succeed in starting it or not. 9. If water has been ingested into the PVT follow the procedure on
page 105 for drying.
123
MAINTENANCE Battery
Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (black) cable last.
Your vehicle has a maintenance-free battery. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
Battery Removal 1. Remove the drivers seat. See page 30. 2. Disconnect the black (negative) battery cable first. 3. Disconnect the red (positive) battery cable last. 4. Remove the battery hold-down strap. 5. Lift the battery out of the vehicle.
WARNING
124
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 125 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. Coat the terminals with dielectric grease or petroleum jelly. 4. Secure the battery hold-down strap. 5. Connect and tighten the red (positive) cable first. 6. Connect and tighten the black (negative) cable last. 7. Verify that cables are properly routed. 8. Reinstall the seat.
Battery Storage Whenever the vehicle is not used for a period of three months or more, recharge the battery about once a month to make up for normal self- discharge (see page 125), or use a POLARIS Battery Tender, which can be left connected during the storage period. Battery Tender will automatically charge the battery if voltage drops below a pre- determined point. See page 134 for the part numbers of POLARIS products. During the storage period, park the vehicle out of the sun in a cool, dry place or remove the battery and store it in a cool, dry place.
125
MAINTENANCE Battery Battery Charging The following battery charging instructions apply only to the installation of a maintenance-free battery. Read all instructions before proceeding with the installation of this battery. The maintenance-free battery is already filled with electrolyte and has been fully charged at the factory. Never pry the battery caps off or add any other fluid to this battery. Always keep a maintenance-free battery fully charged. Since the battery caps cannot be removed, you must use a voltmeter or multimeter to measure DC voltage. WARNING! An overheated battery may explode, causing severe injury or death. Always watch charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool before resuming charging.
For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or greater. 2. If the voltage is less than 12.8 volts, recharge the battery at 5 amps
or less until battery voltage is 12.8 volts or greater, at least 1-2 hours after the charger has been removed.
3. When using an automatic charger, refer to the charger manufacturers instructions for recharging.
126
MAINTENANCE Battery Battery Charging Always verify battery condition before and 1-2 hours after the end of charging.
State of Charge Voltage Action
Charge Time (Using constant current
charger @ standard amps specified on top of battery)
100% 12.8-13.0 volts None, check at 3 mos. from date of
manufacture
None required
75%-100% 12.5-12.8 volts May need slight charge, if no charge given,
check in 3 months
3-6 hours
50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours, verify state of charge
0%-25% 11.5 volts or less Needs charge with desulfating charger
At least 20 hours
127
MAINTENANCE Cleaning and Storage Washing the Vehicle Keeping your POLARIS vehicle clean will not only improve its appearance but it can also extend the life of various components. NOTICE: Water in the PVT system could
cause the drive belt to become wet and slip in the clutches. Always avoid spraying water directly toward any intake pre-filters.
High water pressure may damage the radiator fins and impair the radiators effectiveness. High pressure may also damage other vehicle components.
Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of mild soap and water. 1. Use a professional-type washing cloth, cleaning the upper body first
and the lower parts last. 2. Rinse with clean water frequently. 3. Dry surfaces with a chamois to prevent water spots.
Washing Tips Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the finish.
PVT Intake Pre-Filter
128
MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning (not recommended), exercise extreme caution. The water may damage components and could remove paint and labels. Avoid directing the water stream at the following items: Wheel bearings Radiator Transmission seals Brakes Cab and body panels Labels and decals Electrical components and wiring Air intake components If warning and safety labels are damaged, contact your POLARIS dealer for free replacement. Grease all zerk fittings immediately after washing. Allow the engine to run for a while to evaporate any water that may have entered the engine or exhaust system.
Polishing the Vehicle POLARIS recommends the use of common household aerosol furniture polish for polishing the finish on your POLARIS vehicle. Follow the instructions on the container.
Polishing Tips Avoid the use of automotive products, some of which can scratch the
finish of your vehicle. Always use clean cloths and pads for cleaning and polishing. Old or
reused cloths and pads may contain dirt particles that will scratch the finish.
129
MAINTENANCE Cleaning and Storage Storage Tips NOTICE: Starting the engine during the storage period will disturb the
protective film created by fogging and damage could occur. Never start the engine during the storage period.
Clean the Exterior Make any necessary repairs and clean the vehicle as recommended. See page 127.
Stabilize the Fuel 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel
Stabilizer. Follow the instructions on the container for the recom- mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and removes carbon deposits from pistons, rings, valves and exhaust systems.
3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the entire fuel delivery system.
Oil and Filter Change the oil and filter. See page 90.
Air Filter / Air Box Replace the air filter. See page 107. Clean the air box.
Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 81. Demand drive fluid (front gearcase) Rear gearcase fluid (if equipped) Transmission fluid Brake fluid (change every two years and any time the fluid looks dark
or contaminated) Coolant (test strength/fill)
130
MAINTENANCE Cleaning and Storage Storage Tips Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 81. Fog the Engine 1. Treat the fuel system with POLARIS Carbon Clean. Follow the
instructions on the container. Start the engine. Allow it to idle for several minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes, use a section of clear 1/4 hose and a small plastic squeeze bottle filled with the pre-measured amount of oil. Do this carefully! If you miss the plug holes, oil will drain from the spark plug cavities into the hole at the front of the cylinder head, and appear to be an oil leak.
3. Reinstall the spark plugs. Torque to specification. See page 97. 4. Apply dielectric grease to the inside of each spark plug cap. Do not
reinstall the caps onto the plugs at this step. 5. Turn the engine over several times. Oil will be forced in and around
the piston rings and ring lands, coating the cylinder with a protec- tive film of fresh oil.
6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should be completely drained of gasoline.
7. Reinstall the spark plug caps to the spark plugs.
Battery Maintenance See pages 124-126 for storage and charging procedures.
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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MAINTENANCE Cleaning and Storage Removal from Storage 1. Charge the battery if necessary. 2. Make sure the spark plug is tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section
on page 52. Tightness of the bolts, nuts and other fasteners should be checked by an authorized POLARIS dealer.
5. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page 81.
WARNING! Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness or death. Never run an engine in an enclosed area.
Transporting the Vehicle Follow these procedures when transporting the vehicle. 1. Place the transmission in PARK. Stop the engine. 2. Remove the key to prevent loss during transporting. 3. Secure the fuel cap and seats. Ensure that the seats are attached cor-
rectly and are not loose. WARNING! Cargo and other loose vehicle parts may fly off while transporting this vehicle. Secure or remove all cargo, and inspect the unit for loose parts prior to transport.
4. Always tie the frame of the POLARIS vehicle to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front control arm bolt pockets.
2 Front Tie-Down Points 2 Rear Tie-Down Points
(or Tow Loop)
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SPECIFICATIONS RZR XP 1000
Gross Vehicle Weight 998 kg (2200 lbs.) Dry Weight 625.5 kg (1379 lbs.) Test GVW - Rollover Protection System (ROPS)
1247 kg (2750 lbs.) per OSHA 29 CFR 1928.53
Rear Cargo Box Capacity 136 kg (300 lbs.) Maximum Weight Capacity (Payload)
336 kg (740 lbs.) (including riders, cargo and accessories)
Fuel Capacity 36 liters (9.5 gal.) Engine Oil Capacity 2.4 liters (2.5 qts.) Coolant Capacity 5.1 liters (5.44 qts.) Demand Drive Fluid Capacity 251 ml (8.5 oz.) Transmission Oil Capacity 1.3 liters (44 oz.)
Turf Models: 1.2 l (40.5 oz.) Overall Length/Width/Height 302.3/162.5/187.3 cm (119/64/73.75 in.) Wheelbase 228.6 cm (90 in.) Ground Clearance 34.3 cm (13.5 in.) Engine 4-Stroke DOHC Twin Cylinder Displacement 999 cc Bore x Stroke 93mm x 73.5mm Alternator Output 560 W @ 3000 RPM Compression Ratio 10.5:1 Starting System Electric Fuel System Electronic fuel injection Ignition System ECU Spark Plug / Gap XG4YCX/ 0.7-0.8 mm Front Suspension Independent double a-arm with 40.6 cm (16 in.)
travel Rear Suspension Independent trailing arms with 45.7 cm (18 in.)
travel
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SPECIFICATIONS
Clutching Please see your POLARIS dealer for clutching specifications.
RZR XP 1000 Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Dual Range P/R/N/L/H Tire Size - Front 29x9-14 Tire Size - Rear 29x11-14 Tire Pressure Front: 110 kPa (16 psi)
Rear: 110 kPa (16 psi) Brakes, Front/Rear Foot Activated, 4-wheel hydraulic disc Headlights 2 dual beam LED cluster Taillights 2 LED cluster Brake Lights 2 LED cluster Instrument Cluster Analog and LCD Auxiliary DC Outlet 12V
Output Gear Ratios Rear
High Gear 10.73 Low Gear 22.79 Reverse 20.41
Front (including front drive) High Gear 11.42 Low Gear 24.25 Reverse 21.73
Drive Ratio - Front 3.182:1
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POLARIS PRODUCTS Part Number Description
Engine Lubricant 2870791 Fogging Oil (355 ml/12 oz. Aerosol)
2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (.95 l/1 qt.)
2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (3.8 l/1 gal.)
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (.95 l/1 qt.)
2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (3.8 l/1 gal.)
Gearcase / Transmission Lubricants 2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid
(.95 l/1 qt.)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (3.8 l/1 gal.)
2877922 Demand Drive Fluid (.95 l/1 qt.)
2877923 Demand Drive Fluid (3.8 l/1 gal.)
2870465 Pump for 3.8 l/1 gal. Jug
Coolant 2880514 Antifreeze 50/50 Premix (.95 l/1 qt.)
2880513 Antifreeze 50/50 Premix (3.8 l/1 gal.)
Grease / Specialized Lubricants 2871312 Grease Gun Kit, All Season Grease
2871322 All Season Grease (89 ml/3 oz. cartridge)
2871423 All Season Grease (414 ml/14 oz. cartridge)
2876160 ATV Angle Drive Fluid (.95 l/1 qt.)
2872276 ATV Angle Drive Fluid (9.5 l/2.5 gal.)
2871460 Premium Starter Grease
2871515 U-Joint Grease (89 ml/3 oz. cartridge)
2871551 U-Joint Grease (414 ml/14 oz. cartridge)
2871329 Dielectric Grease (Nyogel)
Additives / Miscellaneous 2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
135
TROUBLESHOOTING Drive Belt Wear/Burn
Possible Cause Solution Driving onto a pickup or tall trailer in high range
Use low range during loading.
Starting out going up a steep incline
Use low range. See warnings on page 60.
Driving at low RPM or ground speed (5-11 km/h or 3-7 MPH)
Drive at a higher speed or use low range more frequently. See page 36.
Insufficient warm-up at low ambient tempera- tures
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 flex- ible and prevent belt burning.
Slow/easy clutch engage- ment
Use the throttle quickly and effectively.
Hauling heavy cargo/ pushing at low RPM/low ground speed
Use low range only.
Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throttle application to engage clutch. WARNING! Excessive throttle may cause loss of control and vehicle rollover.
Climbing over large objects from a stopped position
Shift the transmission to low range and carefully use fast, brief, aggressive throttle application to engage clutch. WARNING! Excessive throttle may cause loss of control and vehicle rollover.
Belt slippage from water or snow ingestion into the PVT system
Dry out the PVT (see page 105). Prevent water from entering the PVT outlet duct (see page 127). Inspect clutch seals for damage if repeated leaking occurs.
Clutch malfunction See your dealer.
Poor engine performance Check for fouled plugs or foreign material in gas tank or fuel lines. See your dealer.
Slippage from failure to warm up belt
Always warm up the belt by operating below 48 km/h (30 MPH) for 1.5 km (one mile) and for 8 km (5 miles) or more when temperature is below freezing.
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and/or clutch. See page 50.
Failed belt Remove the belt and clean away any debris from the clutch box, clutch duct and engine compartment. Install a new belt. WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage and severe injury or death. See page 104.
136
TROUBLESHOOTING Engine Doesn't Turn Over
Engine Turns Over, Fails to Start
Engine Backfires
Possible Cause Solution Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Loose electronic control box connections Inspect, clean, reinstall connectors
Mechanical failure See your dealer
Possible Cause Solution Out of fuel Refuel
Clogged fuel filter See your dealer
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plugs Inspect plugs and replace if necessary
No spark to spark plug Inspect plugs and replace if necessary
Water or fuel in crankcase Immediately see your dealer
Low battery voltage Recharge the battery to 12.8 VDC
Loose ignition connections Check all connections and tighten
Mechanical failure See your dealer
Possible Cause Solution Out of fuel Refuel
Weak spark from spark plug Inspect, clean and/or replace spark plugs
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires See your dealer
Incorrect ignition timing See your dealer
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel
Exhaust leak Check all connections
Mechanical failure See your dealer
137
TROUBLESHOOTING Engine Pings or Knocks
Engine Runs Irregularly, Stalls or Misfires
Possible Cause Solution Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Possible Cause Solution Fouled or defective spark plugs Inspect, clean and/or replace spark plugs
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plugs
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line or filter
Inspect and replace
Kinked idle air control lines Inspect; rotate lines to remove kink
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and replace
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure See your dealer
Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter See your dealer
Low fuel pressure See your dealer
138
TROUBLESHOOTING Engine Stops or Loses Power
Possible Cause Solution Out of fuel Refuel
Kinked or plugged fuel tank vent line or filter
Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plugs Inspect, clean and/or replace spark plug
Worn or defective spark plug wires See your dealer
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and replace
Clogged intake pre-filter Inspect and clean (with soapy water) or replace
Other mechanical failure See your dealer
Overheated engine Clean radiator screen and core, clean engine exterior, check coolant level, see your dealer if condition persists
139
WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a TWO YEAR LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
Registration At the time of sale, the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration Form will be your proof of warranty coverage. If you have not signed the original registration and received the customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set-up will void your warranty coverage.
Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This warranty also does not cover any vehicle, component, or part that has been altered structurally, modified, neglected, improperly maintained or used for racing, competition or purposes other than for which it was designed. This warranty excludes damages or failures resulting from improper lubrication; improper engine timing; improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty period expires or by an unauthorized repair center.
140
WARRANTY Warranty Coverage And Exclusions: Limitations Of Warranties And Remedies This warranty excludes damages or failures caused by abuse, accident, fire, or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components, general wear items, or any parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were not designed or not intended, including but not limited to the following items:
Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this warranty. This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels, meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of profits, or loss of vacation or personal time. THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION, REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE 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 OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL, INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE TWO YEAR WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW.
Wheels and tires Finished and unfinished surfaces Suspension components Carburetor/Throttle body components Brake components Engine components Seat components Drive belts Clutches and components Hydraulic components and fluids Steering components Circuit breakers/Fuses Batteries Electronic components Light bulbs/Sealed beam lamps Spark plugs Filters Sealants Lubricants Coolants Bushings Bearings
141
WARRANTY How To Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty service. In the Country where your product was purchased: Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the Country where your product was purchased: If you are traveling temporarily outside the country where your product was purchased, you should take your product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be authorized to perform the warranty repair. If you move: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Product importation rules vary considerably from country to country. You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage. You may also be required to obtain documentation from POLARIS in order to register your product in your new country. You should warranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle. If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied. You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product.
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.
142
WARRANTY Notice If your product is registered outside of the country where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty. Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance, they will contact the appropriate person at POLARIS. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or in different countries. If any of the above terms are void because of federal, state, local law, all other warranty terms will remain in effect.
143
MAINTENANCE LOG Use the following chart to record periodic maintenance.
DATE km (MILES) OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
144
MAINTENANCE LOG
DATE km (MILES) OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
145
MAINTENANCE LOG
DATE km (MILES) OR HOURS
TECHNICIAN SERVICE PERFORMED / COMMENTS
146
INDEX A
Access Panel Cargo Box . . . . . . . . . . . . . . . . . . 33 Engine . . . . . . . . . . . . . . . . . . . . . 33
Access Panels for Service . . . . . . . . 33 Accessory Outlets . . . . . . . . . . . . . . 26 Adjustment
Hand Hold. . . . . . . . . . . . . . . . . . 31 Seat . . . . . . . . . . . . . . . . . . . . . . . 30 Steering Wheel . . . . . . . . . . . . . . 29
Age Restrictions. . . . . . . . . . . . . . . . 14 Air Filter . . . . . . . . . . . . . . . . . . . . 107 Air Filter Cleaning. . . . . . . . . . . . . 107 All Wheel Drive
Disengaging AWD . . . . . . . . . . . 41 Lock/Unlock the Differential . . . 41 AWD Switch. . . . . . . . . . . . . . . . 28 AWD System . . . . . . . . . . . . . 40-41
Arrester, Spark, Warning. . . . . 108-109 Auxiliary Outlets . . . . . . . . . . . . . . . 26 AWD Switch . . . . . . . . . . . . . . . 28, 40 AWD System. . . . . . . . . . . . . . . . 40-41 Axle Nut Torque . . . . . . . . . . . . . . 117
B Battery . . . . . . . . . . . . . . . . . . 123-126
Charging . . . . . . . . . . . . . . . 125-126 Installation . . . . . . . . . . . . . . . . 124 Removal . . . . . . . . . . . . . . . . . . 123 Storage . . . . . . . . . . . . . . . . . . . 124
Before Riding. . . . . . . . . . . . . . . . . . 52 Belt Burning. . . . . . . . . . . . . . . . . . 135 Belt Life . . . . . . . . . . . . . . . . . . . . . . 67 Belt Replacement. . . . . . . . . . . 104-105 Belt Wear . . . . . . . . . . . . . . . . . . . . 135 Belts, Seat . . . . . . . . . . . . . . . . . . 34-35 Boots . . . . . . . . . . . . . . . . . . . . . . . . . 9 Brake Fluid . . . . . . . . . . . . . . . . . . 112 Brake Inspection . . . . . . . . . . . . . . 111 Brake Lever, Park . . . . . . . . . . . . . . 38 Brake Light . . . . . . . . . . . . . . . . . . 120 Brake Pedal . . . . . . . . . . . . . . . . . . . 37 Brake System Break-in . . . . . . . . . . 51 Brakes . . . . . . . . . . . . . . . . . . . 110-112 Braking . . . . . . . . . . . . . . . . . . . . . . 55 Break-In Period . . . . . . . . . . . . . . 50-51 Burning Belts . . . . . . . . . . . . . . . . . 135
C Cab Doors . . . . . . . . . . . . . . . . . . . . . 34 Cab Frame, ROPS . . . . . . . . . . . . . . . 39 Cap, Fuel . . . . . . . . . . . . . . . . . . . . . . 33 Cargo . . . . . . . . . . . . . . . . . . . . . . 66-67 Cargo Box Access Panel . . . . . . . . . . 33 Changing Gears . . . . . . . . . . . . . . . . . 36 Chart, Periodic Maintenance . . . . 81-85 Check Engine Indicator . . . . . . . . . . . 49 Cleaning and Storage. . . . . . . . 127-131 Cleaning the Air Filter. . . . . . . . . . . 107 Cleaning the Exhaust System . . . . . 109 Cleaning the Spark Arrestor . . . . . . 109 Clothing . . . . . . . . . . . . . . . . . . . . . . . . 9 Clutching . . . . . . . . . . . . . . . . . . . . . 133 Component Locations . . . . . . . . . . . . 25 Condition, Spark Plugs . . . . . . . . . . . 97 Coolant Level, Overflow Bottle . . . 102 Coolant Level, Radiator. . . . . . . . . . 101 Coolant, Adding. . . . . . . . . . . . . . . . . 99 Coolant, Changing . . . . . . . . . . . 99, 101 Coolant, Replacing . . . . . . . . . . . . . 101 Cooling Fan . . . . . . . . . . . . . . . . . . . 100 Cooling System . . . . . . . . . . . . 101-102 Cooling System Operation. . . . . 99-100 Cover for Storage. . . . . . . . . . . . . . . 130
D Declaration of Conformity. . . . . . . . . . 5 Demand Drive Fluid . . . . . . . . . . 94-95 Differential, Lock/Unlock . . . . . . . . . 41 Disengaging AWD . . . . . . . . . . . . . . 41 Display Units, Standard/Metric . . . . . 46 Doors . . . . . . . . . . . . . . . . . . . . . . . . . 34 Drive Belt Wear. . . . . . . . . . . . . . . . 135 Drivetrain Break-In . . . . . . . . . . . . . . 51 Driving Downhill. . . . . . . . . . . . . . . . 61 Driving in Reverse. . . . . . . . . . . . . . . 64 Driving on a Sidehill . . . . . . . . . . . . . 61 Driving on Slippery Surfaces . . . . . . 59 Driving Over Obstacles . . . . . . . . . . . 63 Driving Procedures . . . . . . . . . . . 56-57 Driving Through Water . . . . . . . . . . . 62 Driving Uphill . . . . . . . . . . . . . . . . . . 60 Driving with Passengers . . . . . . . . . . 58 Driving, After Driving in Water . . . 105 Drying the Transmission . . . . . . . . . 105
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INDEX E
Electromagnetic Interference . . . . . . 80 Electronic Power Steering . . . . . . . . 29 Emission Control, Exhaust . . . . . . . . 80 Emission Control, Noise . . . . . . . . . . 80 Engaging AWD. . . . . . . . . . . . . . . . . 40 Engine Access Panel . . . . . . . . . . . . . 33 Engine Break-In . . . . . . . . . . . . . 50-51 Engine Fogging. . . . . . . . . . . . . . . . 130 Engine Intake Pre-Filter . . . . . . . . . 106 Engine Oil . . . . . . . . . . . . . . . . . . 88-91 Engine Starting . . . . . . . . . . . . . . . . . 54 Engine Stopping . . . . . . . . . . . . . . . . 54 EPS . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Equipment Modifications . . . . . . . . . 24 Error Codes, Engine . . . . . . . . . . . . . 49 Exhaust Cleaning . . . . . . . . . . . . . . 109 Exhaust Emission Control System . . 80 Exhaust System Warning . . . . 108-109 Eye Protection. . . . . . . . . . . . . . . . . . . 9
F Fan, Cooling . . . . . . . . . . . . . . . . . . 100 Filter Care During Storage . . . . . . . 129 Filter Cleaning, Air . . . . . . . . . . . . . 107 Filter Systems . . . . . . . . . . . . . 106-107 Filter, Air Filter. . . . . . . . . . . . . . . . 107 Fluid
Demand Drive . . . . . . . . . . . . 94-95 Front Gearcase . . . . . . . . . . . . 94-95 Main Gearcase . . . . . . . . . . . . 92-93 Transmission . . . . . . . . . . . . . 92-93
Fluid Change Demand Drive . . . . . . . . . . . . . . . 95 Front Gearcase . . . . . . . . . . . . . . . 95 Main Gearcase . . . . . . . . . . . . . . . 93 Transmission . . . . . . . . . . . . . . . . 93
Fluid Check Demand Drive . . . . . . . . . . . . . . . 94 Front Gearcase . . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . . 92 Transmission . . . . . . . . . . . . . . . . 92
Fluid Levels During Storage. . . . . . 129 Fluid Recommendations, Gearcase. . 96 Fluid, Brake . . . . . . . . . . . . . . . . . . 112 Fogging the Engine. . . . . . . . . . . . . 130 Fouled Plugs . . . . . . . . . . . . . . . . . . . 97 Freeplay, Steering Wheel . . . . . . . . 119 Fuel Cap . . . . . . . . . . . . . . . . . . . . . . 33
F Fuel Safety . . . . . . . . . . . . . . . . . . . . 22 Fuel Stabilizer . . . . . . . . . . . . . . . . . 129 Fuel Tank Filler Cap. . . . . . . . . . . . . 33 Fuse/Relay Center. . . . . . . . . . . . . . . 98
G Gap, Spark Plug . . . . . . . . . . . . . . . . 96 Gasoline Handling . . . . . . . . . . . . . . 22 Gear Selector . . . . . . . . . . . . . . . . . . 36 Gearcase Capacities . . . . . . . . . . . . . 96 Gearcase Oil
Demand Drive . . . . . . . . . . . . 94-95 Front . . . . . . . . . . . . . . . . . . . . 94-95 Main . . . . . . . . . . . . . . . . . . . . 92-93
Gearcase Specifications . . . . . . . . . . 96 Gearcases . . . . . . . . . . . . . . . . . . 92-96
Demand Drive . . . . . . . . . . . . 94-95 Front Gearcase . . . . . . . . . . . . 94-95 Main Gearcase . . . . . . . . . . . . 92-93 Specification Chart. . . . . . . . . . . . 96 Transmission . . . . . . . . . . . . . 92-93
Gears, shifting. . . . . . . . . . . . . . . . . . 36 Gloves . . . . . . . . . . . . . . . . . . . . . . . . . 9
H Hand Hold, Passenger. . . . . . . . . . . . 31 Hauling a Load . . . . . . . . . . . . . . 66-67 Hauling Cargo. . . . . . . . . . . . . . . 66-67 Hazard Switch. . . . . . . . . . . . . . . . . . 26 Headlight Replacement. . . . . . . . . . 120 Helmet. . . . . . . . . . . . . . . . . . . . . . . . . 8 High Beam Switch . . . . . . . . . . . . . . 27 Hood Removal . . . . . . . . . . . . . . . . . 32 Horn Switch . . . . . . . . . . . . . . . . . . . 27
I Indicator Lamps . . . . . . . . . . . . . . . . 43 Inspection, Axle Nuts . . . . . . . . . . . 117 Inspection, Brakes. . . . . . . . . . . . . . 111 Inspection, Pre-Ride . . . . . . . . . . . . . 52 Inspection, Steering Wheel . . . . . . . 119 Inspection, Wheel Nuts. . . . . . . . . . 117 Installation, Battery. . . . . . . . . . . . . 124 Installation, Wheels . . . . . . . . . . . . 118 Instrument Cluster . . . . . . . . . . . 42-49 Interference, Electromagnetic. . . . . . 80
K Key, Periodic Maintenance Chart. . . 82
148
INDEX L
Light Switch. . . . . . . . . . . . . . . . . . . 27 Lights . . . . . . . . . . . . . . . . . . . 120-121
Headlight Beam Adjustment. . . 121 Headlight Replacement. . . . . . . 120 Tail/Brake/Signal Lights. . . . . . 120
Loads, Towing . . . . . . . . . . . . . . . . . 68 Low Beam Adjustment . . . . . . . . . 121 Lubricant Part Numbers. . . . . . . . . 134 Lubrication for Storage . . . . . . . . . 130 Lubrication Recommendations . . 86-87
M Maintenance, Periodic . . . . . . . . . 81-85 Metric Display . . . . . . . . . . . . . . . . . 46 Mirrors . . . . . . . . . . . . . . . . . . . . . . . 29 Mode Button . . . . . . . . . . . . . . . . . . 42
N New Driving Procedures . . . . . . . . . 56 New Operator Driving Procedures . 57 Noise Emission Control System . . . 80
O Obstacles . . . . . . . . . . . . . . . . . . . . . 63 Oil
Demand Drive. . . . . . . . . . . . . 94-95 Engine . . . . . . . . . . . . . . . . . . . 88-91 Front Gearcase . . . . . . . . . . . . 94-95 Main Gearcase . . . . . . . . . . . . 92-93 Transmission . . . . . . . . . . . . . . 92-93
Oil and Filter Care During Storage 129 Oil Change
Demand Drive. . . . . . . . . . . . . . . 95 Engine Oil . . . . . . . . . . . . . . . . 90-91 Front Gearcase . . . . . . . . . . . . . . 95 Main Gearcase . . . . . . . . . . . . . . 93 Transmission . . . . . . . . . . . . . . . . 93
Oil Check Demand Drive. . . . . . . . . . . . . . . 94 Engine Oil . . . . . . . . . . . . . . . . . . 89 Front Gearcase . . . . . . . . . . . . . . 94 Main Gearcase . . . . . . . . . . . . . . 92 Transmission . . . . . . . . . . . . . . . . 92
Oil Recommendations . . . . . . . . . . . 88 Operation, Cooling System . . . . 99-100 Operation, Transmission . . . . . 103-105 Outlets, Auxiliary . . . . . . . . . . . . . . 26 Overflow Bottle Coolant Level . . . 102
P Park Brake Lever . . . . . . . . . . . . . . . . 38 Parking on an Incline. . . . . . . . . . . . . 65 Parking the Vehicle . . . . . . . . . . . . . . 55 Passenger Hand Hold Adjustment. . . 31 Periodic Maintenance Chart . . . . 81-85 Plug Condition. . . . . . . . . . . . . . . . . . 97 Plug Gap . . . . . . . . . . . . . . . . . . . . . . 96 Plug Torque . . . . . . . . . . . . . . . . . . . . 96 Plugs, Fouled . . . . . . . . . . . . . . . . . . . 97 Plugs, Spark . . . . . . . . . . . . . . . . . 96-97 Polaris Products . . . . . . . . . . . . . . . . 134 Polishing the Vehicle. . . . . . . . . . . . 128 Power Steering. . . . . . . . . . . . . . . . . . 29 Pre-Filters, Intake . . . . . . . . . . . . . . 106 Pre-Ride Inspection . . . . . . . . . . . . . . 52 PVT Break-In . . . . . . . . . . . . . . . . . . 51 PVT Drying . . . . . . . . . . . . . . . . . . . 105 PVT Intake Pre-Filter . . . . . . . . . . . 106 PVT System Operation . . . . . . 103-105 PVT, Cleaning Debris . . . . . . . 104-105
R Radiator . . . . . . . . . . . . . . . . . . . . . . 100 Radiator Coolant Level . . . . . . . . . . 101 Refueling Safety . . . . . . . . . . . . . . . . 22 Registration, Warranty. . . . . . . . . . . 139 Removal, Battery . . . . . . . . . . . . . . . 123 Removal, Seat . . . . . . . . . . . . . . . . . . 30 Removal, Wheels. . . . . . . . . . . . . . . 118 Removing the Vehicle from Storage 131 Reverse . . . . . . . . . . . . . . . . . . . . . . . 64 Rider Information Center. . . . . . . 44-49 Riding Gear . . . . . . . . . . . . . . . . . . . 8-9 Rollover Protective Structure . . . . . . 39 ROPS Cab Frame. . . . . . . . . . . . . . . . 39
S Safe Operation Practices . . . . . . . . . . 53 Safety Labels . . . . . . . . . . . . . . . . 10-13 Safety Symbols . . . . . . . . . . . . . . . . . . 4 Safety Training . . . . . . . . . . . . . . . . . . 7 Safety Warnings . . . . . . . . . . . . . 14-24 Safety, Winch Maintenance. . . . . . . . 79 Seat Adjustment. . . . . . . . . . . . . . . . . 30 Seat Belts . . . . . . . . . . . . . . . . . . . 34-35 Seat Removal. . . . . . . . . . . . . . . . . . . 30 Selector, Gear . . . . . . . . . . . . . . . . . . 36
149
INDEX S
Service Access Panels. . . . . . . . . . . . 33 Severe Use Definition . . . . . . . . . . . . 81 Shifting Gears . . . . . . . . . . . . . . . . . . 36 Shock Compression . . . . . . . . . . . . 116 Shock Loading the Winch. . . . . . . . . 78 Signal Words. . . . . . . . . . . . . . . . . . . . 4 Spark Arrester . . . . . . . . . . . . . . . . . . 80 Spark Arrester Warning . . . . . 108-109 Spark Arrestor Cleaning . . . . . . . . . 109 Spark Plug Condition . . . . . . . . . . . . 97 Spark Plug Gap . . . . . . . . . . . . . . . . . 96 Spark Plug Removal . . . . . . . . . . . . . 97 Spark Plug Torque . . . . . . . . . . . . . . 96 Spark Plugs . . . . . . . . . . . . . . . . . 96-97 Spark Plugs, Fouled . . . . . . . . . . . . . 97 Specifications, Gearcase . . . . . . . . . . 96 Speedometer . . . . . . . . . . . . . . . . . . . 42 Spring Preload. . . . . . . . . . . . . 113-115 Stabilizing the Fuel . . . . . . . . . . . . . 129 Starting the Engine . . . . . . . . . . . . . . 54 Steering Wheel Adjustment . . . . . . . 29 Steering Wheel Inspection . . . . . . . 119 Stopping the Engine . . . . . . . . . . . . . 54 Storage . . . . . . . . . . . . . . . . . . 127-131 Storage and Inspection . . . . . . . . . . 130 Storage and Lubrication . . . . . . . . . 130 Storage Area . . . . . . . . . . . . . . . . . . 130 Storage, Battery . . . . . . . . . . . . . . . 124 Storage, Covers . . . . . . . . . . . . . . . . 130 Storage, Fluid Levels . . . . . . . . . . . 129 Storage, Oil and Filter. . . . . . . . . . . 129 Storage, Removal . . . . . . . . . . . . . . 131 Suspension Settings . . . . . . . . 113-116 Switches
AWD Switch . . . . . . . . . . . . . 28, 40 Hazard Switch . . . . . . . . . . . . . . . 26 High Beam Switch . . . . . . . . . . . . 27 Horn Switch . . . . . . . . . . . . . . . . . 27 Light Switch. . . . . . . . . . . . . . . . . 27 Mode Button . . . . . . . . . . . . . . . . 42 Turn Signal Lever . . . . . . . . . . . . 28
T Tachometer . . . . . . . . . . . . . . . . . . . . 48 Taillight. . . . . . . . . . . . . . . . . . . . . . 120 Throttle Pedal . . . . . . . . . . . . . . . . . . 37 Tire Tread Depth. . . . . . . . . . . . . . . 117 Tires . . . . . . . . . . . . . . . . . . . . 117-118 Torque, Axle Nuts . . . . . . . . . . . . . 117 Torque, Spark Plug . . . . . . . . . . . . . . 96 Torque, Wheel Nut . . . . . . . . . . . . . 117 Towing Loads . . . . . . . . . . . . . . . . . . 68 Training. . . . . . . . . . . . . . . . . . . . . . . . 7 Transmission Oil. . . . . . . . . . . . . 92-93 Transmission Operation . . . . . 103-105 Transmission, Drying . . . . . . . . . . . 105 Transporting the Vehicle . . . . . . . . 131 Tread Depth, Tire . . . . . . . . . . . . . . 117 Turn Signal Lamp . . . . . . . . . . . . . . 120 Turn Signal Lever . . . . . . . . . . . . . . . 28
V Vehicle Identification Numbers . . . . . 6 Vehicle Immersion . . . . . . . . . . . . . 122 Vehicle Transport . . . . . . . . . . . . . . 131
W Warning Symbols . . . . . . . . . . . . . . . . 4 Washing the Vehicle. . . . . . . . 127-128 Water, Immersion of Vehicle . . . . . 122 Wear, Drive Belt . . . . . . . . . . . . . . . 135 Wheel Installation . . . . . . . . . . . . . . 118 Wheel Nut Torque . . . . . . . . . . . . . 117 Wheel Removal . . . . . . . . . . . . . . . 118 Winch Cable Care. . . . . . . . . . . . . . . 77 Winch Maintenance/Service Safety . 79 Winch Operation. . . . . . . . . . . . . 72-76 Winch Safety Precautions. . . . . . 69-71 Winch Shock Loading . . . . . . . . . . . 78
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