PMS 419 2019 GENERAL 1000 EU / ABS Zugmaschine Owner's Manual for Maintenance and Safety
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2019 Owner’s Manual POLARIS GENERAL 1000 EU, ABS, and Zugmaschine
POLARIS®, RANGER®, and POLARIS GENERAL™ are trademarks of POLARIS Industries Inc. Copyright 2018 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.
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.
WELCOME 4
Introduction . . . . . . . Safety . . . . . . . . . . Features and Controls . . Operation . . . . . . . . Winch Guide. . . . . . . Emission Control Systems . Maintenance . . . . . . Specifications . . . . . . POLARIS Products . . . . Troubleshooting . . . . . Warranty . . . . . . . . Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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INTRODUCTION INTRODUCTION This POLARIS vehicle is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. WARNING 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.
INTRODUCTION SAFETY SYMBOLS AND SIGNAL WORDS The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. DANGER DANGER indicates a hazardous situation which, if not avoided, WILL result in death or serious injury. WARNING SAFETY ALERT WARNING indicates a hazardous situation which, if not avoided, COULD result in serious injury.
INTRODUCTION EUROPEAN VIBRATION AND NOISE The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per EN 15997. The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was controlled as indicated by the test procedure(s).
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.
SAFETY SAFETY 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. ROHVA (Recreational Off-Highway Vehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866267-2751. Your POLARIS vehicle is considered an off-road vehicle.
SAFETY SAFE RIDING GEAR Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, overthe-ankle boots and seat belt (if equipped) at all times. Protective gear reduces the chance of injury. RIDER COMFORT Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area.
SAFETY 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. Parents should verify that the young operator has a helmet that fits, and should obtain one of proper size if it does not fit before allowing operation. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label.
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 any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge.
SAFETY GENERAL ALERTS FOR ZUGMASCHINE (7187405) • Always read the owner’s manual. • Never allow anyone under 16 years of age to operate this vehicle. • Always use the cab nets or doors. • Avoid operating in a manner that could result in a rollover. • This vehicle is approved for on-road operation. • Never use alcohol or drugs before or while driving or riding. • Always wear seat belts. • Wear approved helmet, goggles, and protective clothing. • Avoid exhibition driving.
SAFETY SEAT BELT/DRIVE RESPONSIBLY 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.
SAFETY LOAD/PASSENGER/TIRE PRESSURE ALERT (7187406) The Load/Passenger/Tire Pressure warning decal is located on the front panel of the rear cargo box q. WARNING • Never carry passengers in cargo box. • Passengers can be thrown off. This can cause serious injury or death. • If total payload is greater than 500 lbs., the vehicle must be operated in LOW range. IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.
SAFETY GENERAL EU / ZUGMASCHINE GENERAL ABS EU 467 kg 467 kg MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR, PASSENGERS, CARGO, AND ACCESSORIES Read Operation and Maintenance Manual for more detailed loading information.
SAFETY OPERATOR SAFETY WARNING Serious injury or death can result if you do not follow these instructions and procedures, which are outlined in further detail within your owner's manual. • Read this entire manual and all labels carefully. Follow the operating procedures described. • Never allow anyone under the age of 16 to operate this vehicle and never allow anyone without a valid driver's license to operate this vehicle.
SAFETY • Always follow proper procedures for climbing hills as described in this manual. See page 67. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loose surfaces. Never apply throttle suddenly. Never make sudden gear changes. Never go over the top of a hill at high speed. • Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. See page 68.
SAFETY EQUIPMENT MODIFICATIONS Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.
SAFETY USING ALCOHOL OR DRUGS Operating 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 this vehicle. 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.
SAFETY OPERATING WITH A LOAD ON THE VEHICLE The weight of both cargo and operator impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed. • Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle.
SAFETY 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. • NEVER carry fuel or other flammable liquids on this vehicle. Failure to follow this instruction could lead to serious burn injuries or death.
SAFETY 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. OPERATING IN UNFAMILIAR TERRAIN Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
SAFETY IMPROPER TIRE MAINTENANCE Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in the owner's manual and on safety labels. 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.
SAFETY HOT EXHAUST SYSTEMS WARNING Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass. Always inspect the underside of the vehicle and areas near the exhaust system after driving through tall grass, weeds, brush, and other tall ground cover.
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FEATURES AND CONTROLS FEATURES AND CONTROLS COMPONENT LOCATIONS q Console w Headlights e Radiator r Front Bumper/ Brush Guard t Muffler (Spark Arrester) y CV Boot/Rear Caliper u Receiver Hitch i ROPS Cab Frame o Cargo Box a Taillights s PVT Intake Screen 29
FEATURES AND CONTROLS GEAR SELECTOR Low gear is the primary driving range for your vehicle. High gear is intended for use on hard-packed surfaces with light loads. Using high gear for heavy loads, hilly terrain or in wet, muddy conditions will increase the chance of drive belt burning. See the Drive Belt Wear/Burn section on page 129. To shift gears, brake to a complete stop. When the engine is idling, move the lever q to the desired gear.
FEATURES AND CONTROLS SWITCHES IGNITION SWITCH The ignition switch is a four-position, key-operated switch. The key can be removed from the switch when it is in the OFF position. 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.
FEATURES AND CONTROLS WINCH SWITCH Press the top of the rocker switch to spool line out from the winch. Press the bottom of the rocker switch to spool line in to the winch. Move the rocker switch to the center position to stop spooling. HAZARD SWITCH Push the hazard warnings switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.
FEATURES AND CONTROLS 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 q 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 w to signal a right turn.
FEATURES AND CONTROLS FOOT PEDALS BRAKE PEDAL Depress the brake pedal q to slow or stop the vehicle. Apply the brakes while starting the engine. When the brake pedal is depressed, the brake light comes on. Check the brake light before each ride. 1. Turn the ignition switch to the ON position. 2. Apply the brakes. The brake light should come on after about 10 mm (0.4 in.) of pedal travel. THROTTLE PEDAL Push the throttle pedal w down to increase engine speed.
FEATURES AND CONTROLS PARK BRAKE LEVER (IF EQUIPPED) 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.
FEATURES AND CONTROLS SEATS SEAT BELTS This vehicle is equipped with three-point lap and diagonal seat belts for the operator and passengers. Always make sure the seat belts are secured for all riders before operating. The driver’s seat belt is equipped with a seat belt interlock. Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is not secured. WARNING Falling from a moving vehicle could result in serious injury or death.
FEATURES AND CONTROLS 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.
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. 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. Turn the key off and on to reset the unit.
FEATURES AND CONTROLS TRAILER HITCH This vehicle is equipped with a receiver hitch bracket for a trailer hitch and trailer towing equipment. NOTICE To avoid injury and property damage, always heed the warnings and towing capacities outlined in the specification table. Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object. REAR HITCH Use the rear hitch for towing a trailer.
FEATURES AND CONTROLS HITCH REMOVAL / INSTALLATION 1. To remove the hitch, remove the cotter pin and hitch pin. Remove the hitch, then reinstall the hitch pin and secure the cotter pin. Cotter Pin q Hitch Pin w Step 4 Step 5 2. To install the hitch, remove the cotter pin from the hitch pin and remove the hitch pin. 3. Install the hitch to the receiver. 4. Reinstall the hitch pin (from the left side of the hitch) through the bore of both the receiver and the hitch. 5. Reinstall the cotter pin.
FEATURES AND CONTROLS FUEL CAP NOTICE Never use fuel blends with more than 10% ethanol. Engine damage could occur. The fuel tank filler cap q is located on the right side of the vehicle near the passenger seat. Use only unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Unleaded fuel blends with up to 10% ethanol can be used. HOOD Remove the hood to access the radiator pressure cap and coolant overflow bottle. CAUTION Escaping steam can cause burns.
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.
FEATURES AND CONTROLS SPEEDOMETER The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 50. TACHOMETER The tachometer displays engine speed in revolutions per minute (RPM). MODE BUTTON Press and hold the MODE button r to enter or exit the settings menu. Press and release the MODE button to cycle through Area 1 modes and to select an item. TOGGLE BUTTONS Press and release either toggle button t to cycle through the options menu or Area 2 modes.
FEATURES AND CONTROLS 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. 44 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.
FEATURES AND CONTROLS LAMP INDICATES CONDITION Direction Indicators Direction indicators flash when a turn signal is active. Both indicators flash when the hazard signal is active. Brake Failure Alarm Lamp illuminates when Brake System (if Brake Failure Alarm is equipped) detects low pressure in brake hydraulic system. Park Brake Lamp illuminates when the Park Brake is applied. Trailer Indicator The Turn Trailer Indicator is illuminating when the trailer turn signals are active.
FEATURES AND CONTROLS RIDER INFORMATION CENTER q 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) w AWD Indicator This indicator shows whether 2X4 or AWD is active. e Service Indicator A flashing wrench symbol alerts the operator that the preset service interval has been reached. Your POLARIS dealer, or other qualified person, can provide scheduled maintenance.
FEATURES AND CONTROLS MODE INFORMATION DISPLAYS The rider information center contains three areas that display mode information. q Area 1 Modes Description Engine Temperature Temperature of engine coolant Vehicle Speed Speed of vehicle Tachometer Engine speed (RPM) w Area 2 Modes Description Odometer The odometer records and displays the distance traveled by the vehicle. Trip Meters (T1/T2) A trip meter records the distance traveled by the vehicle if reset before each trip.
FEATURES AND CONTROLS ACCESSING MENUS AND OPTIONS GAUGE SETTINGS MENU Press and release the MODE button to cycle through the Area 1 modes until the desired default mode displays. See page 47. Press and hold the MODE button to enter the settings menu. The OPTIONS screen will display for a few seconds. 1. Press and release either toggle button to cycle to the desired option. 2. Press MODE to select the option. 3. Press either toggle button to cycle to the desired setting. 4.
FEATURES AND CONTROLS BACKLIGHT BRIGHTNESS The information center backlight can be set to either blue or red. 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the “BL LEVEL” option. Press MODE to select. 3. Press “UP” button to increase brightness. Press “DOWN” button to decrease brightness. 4. Press MODE to select and exit to the settings menu. CLOCK The clock must be reset any time the battery has been disconnected or discharged. 1.
FEATURES AND CONTROLS DISPLAY UNITS (STANDARD/METRIC) 1. Press and hold the MODE button to enter the settings menu. 2. Press either toggle button to cycle to the desired “UNITS” option (distance, temperature or volume). Press MODE to select. 3. Press either toggle button to cycle to the desired setting. 4. Press MODE to save and exit to the settings menu. TRIP METER Use a trip meter to track the distance traveled during a specific trip or period of time. Reset the meter to zero before traveling. 1.
FEATURES AND CONTROLS PROGRAMMABLE SERVICE INTERVAL The service interval counter is programmed to 25 hours at the factory. As hours of engine operation increase, the counter decreases. The wrench icon will flash for about 10 seconds when the counter reaches zero (0), and each time the key is turned on thereafter, until the counter is reset. When this feature is enabled, it provides a convenient reminder to perform routine maintenance.
FEATURES AND CONTROLS ENGINE ERROR CODES The error screen displays only when the CHECK ENGINE indicator 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 lamp or the EPS lamp illuminates, retrieve the active error codes from the display. q Failure Mode Indicator (FMI) w Suspect Parameter Number (SPN) e Code Count 1.
OPERATION OPERATION WARNING Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. VEHICLE BREAK-IN PERIOD The break-in period for your new vehicle is the first 20 hours of operation, or the time it takes to use the first 2 tanks full of gasoline.
OPERATION PVT BREAK-IN (CLUTCHES/BELT) A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period. If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt.
OPERATION 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. 4. Slowly release the brake pedal and make sure the transmission is in PARK before exiting the vehicle. WARNING A rolling vehicle can cause serious injury. Always place the transmission in PARK when stopping the engine. BRAKING 1. Release the throttle pedal completely.
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.
OPERATION ALL WHEEL DRIVE/REAR DIFFERENTIAL SYSTEM If your model is equipped with a lockable differential, you can choose to operate with an open differential or a closed differential. ENGAGING AWD Press the top of the switch to engage All Wheel Drive (AWD). The 4X4 indicator illuminates in the rider information center to indicate that the vehicle is in AWD. When the AWD switch is on, the front gearcase will automatically engage any time the rear wheels lose traction.
OPERATION 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. To disengage AWD, do the following: 1.
OPERATION NOTICE Damage to the differential can occur if it is engaged while the vehicle is traveling at high speeds or while the rear wheels are spinning. Slow the vehicle to nearly stopped before engaging the differential. WARNING Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill.
OPERATION HAULING CARGO WARNING Hauling cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. WARNING Always follow these precautions when hauling cargo: • Never exceed the maximum weight capacity of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passengers, non-factory installed accessories, loads in the rack or box and the load on the trailer tongue.
OPERATION WARNING • 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. Always attach the tow load to the hitch point designated for your vehicle. • HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS.
OPERATION TOWING LOADS Towing improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when towing: 1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket. 2. When transporting heavy loads and/or when towing, always operate the vehicle in low gear and have ADC activated (if equipped). 3. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. Towing a trailer increases braking distance. 4.
OPERATION DUMPING THE CARGO BOX 1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline. 2. Apply the brakes. Place the transmission in PARK. 3. Ensure that the cargo is positioned evenly or toward the front of the cargo box. 4. Release the tailgate by pulling up on the tailgate latch.
OPERATION TOWING THE GENERAL Towing this vehicle is not recommended. Always transport the vehicle on a trailer or flatbed with all four wheels off the ground. See page 124. If towing a disabled vehicle is unavoidable, place the disabled vehicle’s transmission in neutral. Tow the shortest distance possible. Do not operate faster than 10 MPH (16 km/h). DRIVING PROCEDURE 1. Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots. 2. Perform the pre-ride inspection.
OPERATION DRIVING WITH A PASSENGER 1. Perform the pre-ride inspection. 2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold. 3. Make sure all passengers are wearing helmet, eye protection, gloves, longsleeve shirt, long pants and over-the-ankle boots. 4. Make sure all passengers secure their seat belt. 5. Make sure all cab nets (or doors) are properly secured.
OPERATION DRIVING ON SLIPPERY SURFACES WARNING Skidding or sliding can cause loss of control or rollover (if tires regain traction unexpectedly). When operating on slippery surfaces such as ice or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces. When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding.
OPERATION DRIVING UPHILL Whenever traveling uphill, follow these precautions: 1. Avoid excessively steep hills. 2. ADC Models: Always operate in low gear and engage ADC 4X4 before ascending or descending a hill. 3. Always travel straight uphill. 4. Keep both feet on the floor. 5. Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. 6. Proceed at a steady rate of speed and throttle opening. Never open the throttle suddenly. 7.
OPERATION DRIVING DOWNHILL When driving downhill, follow these precautions: 1. Avoid excessively steep hills. 2. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces. 3. Slow down. Never travel down a hill at high speed. 4. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral. 5.
OPERATION DRIVING THROUGH WATER Your vehicle can operate through water up to a maximum recommended depth equal to the floorboards. NOTE If your vehicle becomes immersed or is operated in water that exceeds the floor level, service is required before starting the engine. Your dealer can provide this service. If it's impossible to bring the vehicle in before starting the engine, perform the service outlined on page 105, and take the vehicle in for service at the first opportunity.
OPERATION DRIVING IN REVERSE Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. 2. Always avoid backing downhill. 3. Back slowly. 4. Apply the brakes lightly for stopping. 5. Avoid turning at sharp angles. 6. Never open the throttle suddenly. PARKING THE VEHICLE 1. Stop the vehicle on a level surface.
WINCH GUIDE WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle. WARNING Improper winch use can result in SEVERE 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.
WINCH GUIDE b. If stacking occurs, stop winching. Follow step 15 of Winch Operation to feed and rewind the cable evenly before continuing the winch operation. 13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning. 14. Never attempt to winch loads that weigh more than the winch’s rated capacity. 15. The winch motor may become hot during winch use.
WINCH GUIDE WINCH OPERATION Read the Winch Safety Precautions in the preceding pages before using your winch. TIP Consider practicing the operation and use of your winch before you actually need to use it in the field. WARNING Improper winch use can result in SEVERE 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.
WINCH GUIDE 4. Always use the hook strap when handling the hook. WARNING Never put your fingers into the hook. This could lead to SEVERE INJURY. • Attach the hook itself onto the load or use a tow strap or chain to secure the load to the winch cable. TIP A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to stretch. WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH.
WINCH GUIDE 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, or other qualified dealer. • If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
WINCH GUIDE b. Lay the damper on top of the mid-point of the winch cable length that is spooled out. c. On a long pull, it may be necessary to stop winching so that the damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper. d. Avoid being directly in line with the winch cable whenever possible. Also, never permit others to stand near or in line with the winch cable during winch operation. 9.
WINCH GUIDE 13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods. 14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again. 15.
WINCH GUIDE 2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable. A kinked winch cable made of wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition. A kinked winch cable made of wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged.
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.
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.
EMISSION CONTROL SYSTEMS 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.
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MAINTENANCE MAINTENANCE PERIODIC MAINTENANCE CHART Any qualified repair shop or person may maintain, replace or repair the emission control devices or systems on your vehicle. An authorized dealer can perform any service that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for emissions-related service, however equivalent parts can be used.
MAINTENANCE MAINTENANCE CHART KEY SYMBOL DESCRIPTION XU Perform these procedures more often for vehicles subjected to severe use. D Have an authorized POLARIS dealer or other qualified person perform these services. 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 or other qualified person perform these services. Perform all services at whichever maintenance interval is reached first.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) MILES (KM) HOURS CLNDR Battery 25 H Monthly 200 (320) Check terminals; clean; test Fuel System 25 H Monthly 200 (320) Inspect; cycle key to pressurize fuel pump; check lines and fittings for leaks and abrasion XU Demand drive fluid (extreme use) 25 H Monthly - Change fluid every 25 hours if ADC is subjected to extreme use. See the Front Gearcase section for details.
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) ITEM HOURS CLNDR MILES (KM) REMARKS XU Transmission oil 100 H 12 M 1000 (1600) Change fluid D Fuel System 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every 2 years XU Cooling Hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks XU Engine mounts 100 H 12 M 1000 (1600) Inspect Exhaust muffler /pipe 100 H 12 M 1000 (1600) Ins
MAINTENANCE MAINTENANCE INTERVAL (WHICHEVER COMES FIRST) HOURS ITEM D XU CLNDR MILES (KM) REMARKS Auxiliary brake (if equipped) - Inspect daily; adjust as needed Headlight aim - Adjust as needed LUBRICATION RECOMMENDATIONS Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart section, 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.
MAINTENANCE ENGINE OIL Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart. Always use the recommended engine oil. Always change the oil filter whenever changing oil. 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.
MAINTENANCE 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. CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components. Access the oil fill cap, dipstick and filter under the cargo box. 1. Remove all cargo from the cargo box. See page 63. 2. Position the vehicle on a level surface. 3. Place the transmission in PARK. 4. Stop the engine. 5.
MAINTENANCE OIL AND FILTER CHANGE Always change the oil and filters at the intervals outlined in the Periodic Maintenance Chart section. Always change the oil filter whenever changing oil. The crankcase drain plug is located on the bottom of the crankcase. Access the drain plug through the access hole in the skid plate under the crankcase (see next page). CAUTION Always remove all cargo from the cargo box before lifting the box to access engine components.
MAINTENANCE 13. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn an additional 3/4 turn. 14. Reinstall the drain plug. Torque the drain plug to 12 ft-lbs (16 Nm). 15. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended oil. Reinstall the fill cap. 16. Start the engine and check for leaks. 17. Stop the engine and wait 15 seconds before removing the dipstick. 18. Remove the dipstick. Wipe it dry with a clean cloth. 19.
MAINTENANCE GEARCASES TRANSMISSION (MAIN GEARCASE) Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart section. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 127 for the part numbers of POLARIS products. OIL CHECK The fluid check/fill plug is located on the rear of the gearcase. Maintain the oil level even with the bottom of the plug hole threads. 1.
MAINTENANCE FRONT GEARCASE Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart. Maintain the oil level even with the bottom thread of the fill plug hole. Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 127 for the part numbers of POLARIS products. ADC Models: Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use.
MAINTENANCE 7. Reinstall the fill plug. Torque to specification. 8. Check for leaks. Discard of used oil properly. GEARCASE SPECIFICATION CHART GEARCASE LUBRICANT CAPACITY FILL PLUG TORQUE DRAIN PLUG TORQUE Main Gearcase (Transmission) AGL Gearcase Lubricant & Transmission Fluid 44 oz. (1300 ml) 10-14 ft. lbs. (14-19 Nm) 10-14 ft. lbs. (14-19 Nm) Front Gearcase Demand Drive Fluid 7.5 oz. (222 ml) 8-10 ft. lbs. (11-14 Nm) 8-10 ft. lbs.
MAINTENANCE SPARK PLUGS SPARK PLUG RECOMMENDATIONS Refer to the Specifications section for the recommended spark plug type for your vehicle. Always torque spark plugs to specification. NOTICE Using non-recommended spark plugs can result in serious engine damage. Always use POLARIS-recommended spark plugs or their equivalent. SPARK PLUG GAP / TORQUE ELECTRODE GAP PLUG TORQUE 0.7-0.8 mm 7 ft. lbs. (9.5 Nm) SPARK PLUG INSPECTION Spark plug condition is indicative of engine operation.
MAINTENANCE 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. The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect throttle body adjustments. WET FOULED PLUG The wet fouled insulator tip is black. A damp oil film covers the firing end.
MAINTENANCE COOLING SYSTEM The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle.
MAINTENANCE OVERFLOW BOTTLE COOLANT LEVEL Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Remove the hood. See page 41. 4. View the coolant level in the overflow bottle. 5.
MAINTENANCE RADIATOR COOLANT LEVEL Check the radiator coolant level ONLY if the overflow bottle is dry. If the overflow bottle contains fluid, the radiator level should NOT be inspected. TIP If the overflow bottle runs completely dry, there may be a leak in the system. Your POLARIS dealer, or other authorized, can inspect the cooling system. 1. Remove the hood. See page 41. CAUTION Escaping steam can cause burns. Never remove the pressure cap while the engine is warm or hot.
MAINTENANCE POLARIS VARIABLE TRANSMISSION (PVT) SYSTEM WARNING Failure to comply with the instructions in this warning can result in severe injury or death. Do not modify any component of the 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.
MAINTENANCE 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 cover and thoroughly clean all debris from the aluminum debris bracket and from the engine compartment. 3.
MAINTENANCE PVT DRYING There may be some instances when water is accidentally 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.
MAINTENANCE VEHICLE IMMERSION WARNING If your vehicle becomes immersed, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle in for service before starting the engine. Your POLARIS dealer, or other qualified person, can provide this service. If it's impossible to take your POLARIS vehicle to a dealer before starting it, follow the steps outlined below: 1. Move the vehicle to dry land, or at the very least, to water below the floorboard. 2.
MAINTENANCE FILTER SYSTEMS AIR FILTER Always change the air filter at the intervals outlined in the Periodic Maintenance Chart. Service the air filter more frequently if the vehicle is operated in wet conditions or at high throttle for extended periods. 1. Lift the cargo box to access the air box. 2. Release the air box cover latches and remove the cover. 3. Remove the air filter. 4. Inspect the air box for oil or water deposits. Wipe away any deposits with a clean cloth. 5.
MAINTENANCE SPARK ARRESTER WARNING • Never operate the vehicle without the spark arrester. • Remove any combustible materials from the area. Failure to heed the following warnings while servicing the spark arrester could result in serious injury or death. • 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. • Do NOT perform service on the spark arrester while the system is HOT.
MAINTENANCE BRAKES The front and rear brakes are hydraulic disc type brakes activated by the brake pedal. WARNING Do not perform maintenance immediately after the vehicle has been operated, as the brake system may become very hot. Serious burns could result from contact with hot brake components. Allow components to cool before proceeding. Always wear eye protection and gloves. BRAKE FLUID Inspect the brake system routinely. Inspect the level of the brake fluid before each operation.
MAINTENANCE BRAKE INSPECTION WARNING Do not apply WD-40 or any petroleum product to brake discs. These types of products are flammable and may also reduce the friction between the brake pad and caliper. 1. Check the brake system for fluid leaks. 2. Check the brake pedal for excessive travel or a spongy feel. 3. Check the friction pads for wear, damage and looseness. 4. Check brake discs for signs of cracks, excessive corrosion, warping or other damage.
MAINTENANCE ABS INSPECTION 1. If the ABS system fails or becomes defective, the ABS symbol will illuminate on the Instrument Cluster. 2. If this occurs, decrease vehicle speed to maximum of 60 km/h. 3. The speed sensors q are located in the front and rear of the vehicle as shown. To inspect the ABS system, check that the air gap of all 4 speed sensors is 0.8-1 mm w. CAUTION Ensure that the ABS sensors are not adjusted outside the appropriate air gap threshold.
MAINTENANCE Rear Right Rear Left 109
MAINTENANCE SUSPENSION SETTINGS (EPS) FRONT/REAR SPRING PRELOAD (EPS) The front and rear suspensions are preload adjustable, with five possible settings. The suspensions are set on the lowest setting at the factory. 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. Always heed the following rules if you make adjustments to this suspension.
MAINTENANCE SUSPENSION SETTINGS (EPS DELUXE) FRONT/REAR SPRING PRELOAD (EPS DELUXE) The front and rear suspensions are preload adjustable. The suspensions are set on the lowest setting at the factory. 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. Always heed the following rules if you make adjustments to this suspension.
MAINTENANCE FRONT/REAR SHOCK COMPRESSION The compression damping clicker knob is located at the top of the shock reservoir. When the knob is turned fully clockwise, the damping is in the fully closed position. 1. Turn the clicker clockwise to increase compression damping. 2. Turn the clicker counter-clockwise to decrease compression damping.
MAINTENANCE TIRES WARNING Operating your vehicle with worn tires will increase the possibility of skidding, loss of control and an accident, which could result in serious injury or death. Always replace tires when the tread depth measures 1/8” (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.
MAINTENANCE WHEEL REMOVAL 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. Stop the engine. 3. Loosen the wheel nuts slightly. 4. Elevate the side of the vehicle by placing a suitable stand under the frame. 5. Remove the wheel nuts and washers. Remove the wheel. WHEEL INSTALLATION 1. Place the transmission in PARK. 2. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation.
MAINTENANCE LIGHTS Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean lights frequently and replace burned out lamps promptly. Do not operate this vehicle at night or in low light conditions until the headlight is replaced. Always make sure lights are adjusted properly for best visibility. When servicing a halogen lamp, don't touch the lamp with bare fingers.
MAINTENANCE HEADLIGHT BEAM ADJUSTMENT 1. Place the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) 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 on the headlights. 5. Observe the headlight aim. The most intense part of the headlight beam should be aimed 8" (20 cm) below the mark placed on the wall.
MAINTENANCE BATTERY Your vehicle has a sealed battery, which requires little maintenance. Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove the corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry off with clean shop towels. Coat the terminals with dielectric grease or petroleum jelly.
MAINTENANCE BATTERY STORAGE Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and recharge as needed to maintain a full charge. See page 118. TIP Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self discharge.
MAINTENANCE 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.
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. When washing the vehicle, always avoid spraying water directly toward the PVT intake screen. High water pressure may damage components. POLARIS recommends washing the vehicle by hand or with a garden hose, using mild soap.
MAINTENANCE WASHING TIPS • • • • Avoid the use of harsh cleaners, which can scratch the finish. Do not use a power washer to clean the vehicle. Do not use medium to heavy duty compounds on the finish. Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and pads may contain dirt particles that will scratch the finish. • Grease all zerk fittings immediately after washing.
MAINTENANCE 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 120. STABILIZE THE FUEL 1. Fill the fuel tank. 2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer or equivalent fuel treatments or stabilizers.
MAINTENANCE FLUID LEVELS Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart section. • • • • 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) FOG THE ENGINE 1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment. Follow the instructions on the container. Start the engine.
MAINTENANCE REMOVAL FROM STORAGE 1. Check the battery electrolyte level and charge the battery if necessary. Install it in the vehicle. Make sure the battery vent hose is routed properly and that it's not pinched or restricted in any way. 2. Make sure spark plugs are tight. 3. Fill the fuel tank with fuel. 4. Check all the points listed in the Daily Pre-Ride Inspection section. Tightness of the bolts, nuts and other fasteners should be checked by an authorized dealer or other qualified service facility. 5.
SPECIFICATIONS SPECIFICATIONS POLARIS GENERAL 1000 EU / ABS / ZUGMASCHINE Gross Vehicle Weight (includes weight of operator, passenger, cargo, accessories) 1268 kg Dry Weight 704 kg (EPS) 719 kg (EPS Deluxe) 720 kg (ABS) 722 kg (ZUG) Test GVW - Rollover Protection System (ROPS) 1268 kg per OECD Code 4 procedure Fuel Capacity 36 L Engine Oil Capacity 2.4 L Coolant Capacity 5.1 L Towing Capacity 680 kg Hitch Tongue Capacity 68 kg Max. Cargo Box Load* 272 kg Overall Length 294.
SPECIFICATIONS POLARIS GENERAL 1000 EU / ABS / ZUGMASCHINE Spark Plug / Gap MR7F / 0.7-0.8 mm Front Suspension Independent Double A-arm w/31 cm of travel Rear Suspension Independent Double A-arm w/33.7 cm of travel Lubrication System Wet Sump Driving System Type Automatic POLARIS Variable Transmission Shift Type Single Lever Dual Range (H/L/N/R/P) Transmission Gear Ratio - High 10.73:1 Transmission Gear Ratio - Low 22.79:1 Transmission Gear Ratio - Reverse 20.41:1 Front Drive Ratio 3.
POLARIS PRODUCTS POLARIS PRODUCTS LUBRICANTS / SERVICE PRODUCTS PRODUCT SIZE (QUANTITY) PART NUMBER 12 oz aerosol (12) 2870791 1 qt (12) 2871517 1 qt (12) 2876244 2 qt (8) 2877490 Fogging Oil PS-4 PS-4 Extreme Duty 1 gal (4) 2876245 1 qt (12) 2878920 2 qt (8) 2878922 1 gal (4) 2878919 1 qt (12) 2878068 1 gal (4) 2878069 AGL Pump for Gallon Jug 3.8 l 2870465 1 qt (12) 2877922 2.
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TROUBLESHOOTING 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 67. Driving at low RPM or ground speed (3-7 MPH) Drive at a higher speed or use low range more frequently. Insufficient warm-up at low ambient temperatures Warm the engine at least 5 minutes.
TROUBLESHOOTING ENGINE DOESN'T TURN OVER POSSIBLE CAUSE SOLUTION Low battery voltage Recharge the battery to 12.
TROUBLESHOOTING ENGINE BACKFIRES POSSIBLE CAUSE SOLUTION Weak spark from spark plug Inspect, clean and/or replace spark plug Incorrect spark plug gap or heat range Set gap to specs or replace plug Old or nonrecommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires Your dealer can assist Mechanical failure Your dealer can assist Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel ENGINE PINGS
TROUBLESHOOTING ENGINE RUNS IRREGULARLY, STALLS OR MISFIRES POSSIBLE CAUSE SOLUTION Fouled or defective spark plug Inspect, clean and/or replace spark plug Worn or defective spark plug wires Your POLARIS dealer, or other qualified person, can assist Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low battery voltage Recharge battery to 12.
WARRANTY WARRANTY LIMITED WARRANTY POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a SIX MONTH 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.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS LIMITATIONS OF WARRANTIES AND REMEDIES This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY 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.
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.
WARRANTY 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.
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MAINTENANCE LOG MAINTENANCE LOG MAINTENANCE LOG Use the following chart to record periodic maintenance.
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7-Way Trailer Connector . . . . . . . . . . . . . 40 A ABS Inspection . . . . . . . . . . . . . . . . . . . . . . . 108 Adding or Changing Coolant . . . . . . . . 97 Age Restrictions . . . . . . . . . . . . . . . . . . . . . . . . 21 Air Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 All Wheel Drive/Rear Differential System . . . . . . . . . . . . . . . . . . . 57 Auxiliary Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . 33 Axle and Wheel Nut Torque Specifications. .
F Fan, Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Filter Systems. . . . . . . . . . . . . . . . . . . . . . . . . 104 Fluid Change Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Front Gearcase . . . . . . . . . . . . . . . . . . . . . . 93 Main Gearcase . . . . . . . . . . . . . . . . . . . . . . 92 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 92 Fluid Check Front Gearcase . . . . . . . . . . . . . . . . . . . . . . 93 Main Gearcase . . . .
Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 92 Oil Level Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 Front Gearcase . . . . . . . . . . . . . . . . . . . . . . 93 Main Gearcase . . . . . . . . . . . . . . . . . . . . . . 92 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . 92 Oil Recommendations . . . . . . . . . . . . . . . . 88 Operator Safety. . . . . . . . . . . . . . . . . . . . . . . . . 19 P Park Brake Lever. . . . . . . . . . . . . . .
Torque, Spark Plug . . . . . . . . . . . . . . . . . . . . 95 Torque, Wheel Nut . . . . . . . . . . . . . . . . . . . . 113 Towing Loads . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Towing the GENERAL . . . . . . . . . . . . . . . . 64 Trailer Hitch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102 Oil . . . . . . . . . . . . . . . . . . .
PMS 419 For your nearest Polaris dealer, visit www.polaris.com Polaris Sales Europe Sarl Place de l'Industrie 2 1180 Rolle, Switzerland Part No.
