WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-3423764 for assistance.
WELCOME Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris owners. We proudly produce an exciting line of utility and recreational products. • Snowmobiles • All-terrain vehicles (ATVs) • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recreational vehicles manufactured in the world today.
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc. Copyright 2008 Polaris Sales 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.
TABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Features and Controls . . . . . . . . . . . . . . . . . . . 28 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Emission Control Systems . . . . . . . . . . . . . . . 74 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Troubleshooting . .
INTRODUCTION 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. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
INTRODUCTION WARNING Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. 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 owner’s manual.
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 Training SAFETY ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV RiderCoursesm available to you and your eligible family members. This training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCoursesm. You were also provided with printed materials that explain safe operating procedures.
SAFETY Safe Riding Gear Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury. Helmet Eye Protection Long Sleeves Gloves Long Pants Boots Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. A passenger (on approved models) should wear a helmet that includes a rigid chin guard.
Safe Riding Gear SAFETY Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a 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 Off-road style gloves with knuckle pads are the best for comfort and protection.
SAFETY Safety Warnings WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures. Operating Without Instruction Operating this ATV without proper instruction increases the risk of an accident.
Safety Warnings SAFETY Handling Gasoline Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel with the engine stopped, and outdoors or in a well ventilated area. • 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.
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 passenger must always wear an approved helmet that fits properly and eye protection (goggles or face shield). Carrying a Passenger Do not carry a passenger until you have at least two hours of driving experience with this vehicle.
Safety Warnings SAFETY Carrying a Passenger in the Cargo Box A passenger riding in the cargo box could fall from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death. Never allow a passenger to ride in the cargo box. Operating on Pavement Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.
SAFETY Safety Warnings Physical Control of the ATV Removing even one hand or foot can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV. If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury. Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation.
Safety Warnings SAFETY Improper Hill Climbing Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 61. Never operate with the differential unlocked ( ) while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See pages 29 and 39. Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn.
SAFETY Safety Warnings Stalling While Climbing a Hill Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn. • Always maintain a steady speed when climbing a hill. • Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. If all forward speed is lost: • Lean forward to keep body weight uphill. A passenger should also lean uphill. • Apply the single lever brakes. • Lock the parking brake when fully stopped.
Safety Warnings SAFETY Operating on Slippery Terrain Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn. Do not operate on excessively rough, slippery or loose terrain until you've learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain.
SAFETY Safety Warnings Improper Tire Maintenance Operating this ATV 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 ATV. Always maintain proper tire pressure as described in the owner's manual and on safety labels. Operating Over Obstacles Improperly operating over obstacles could cause loss of control or overturn. Before operating in a new area, check for obstacles.
Safety Warnings SAFETY Operating Through Deep Water Operating the ATV through deep or fastflowing water could cause the tires to float, causing loss of control or overturn. Avoid operating the ATV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 66): • Travel slowly. • Balance your weight carefully. • Avoid sudden movements. • Maintain a slow and steady forward motion.
SAFETY Safety Warnings Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice. Never operate the ATV on a frozen body of water. Poor Visibility Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only.
Safety Warnings SAFETY Operating a Damaged ATV Operating a damaged ATV can result in an accident. After any overturn or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems. Physical Skills Safe operation of this rider-active vehicle requires good judgement and physical skills.
SAFETY Safety Labels and Locations Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown 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.
Safety Labels and Locations SAFETY General Warning/Discretionary Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper ATV training or instruction • at speeds too fast for your skills or the conditions • on public roads - a collision can occur with another vehicle • with a passenger unless pass
SAFETY Safety Labels and Locations Passenger Safety Warning WARNING PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely Passenger Safety grasp hand holds.
SAFETY Safety Labels and Locations Tire Pressure/Load Warning WARNING Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death. • Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa) • Maximum weight capacity: 705 lbs.
SAFETY Safety Labels and Locations Box Warning Rack Warning + + + Clutch Cover Warning Rack Warning, Front WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 90 lbs. (41 kg) 7174201 Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed.
Safety Labels and Locations SAFETY Reverse Override Warning/AWD Caution WARNING Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse. CAUTION Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. 7175512 Box Warning WARNING Remove flammable material containers from box before filling.
FEATURES AND CONTROLS Switches Headlight Switch Worklight Switch (if equipped) Differential Switch 4X4 Switch Mode/Reverse Override Switch Engine Stop Switch Main Key Switch Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional wheel speed while backing, depress the override switch. WARNING! Activating the override switch while the throttle is open can cause loss of control, which may result in serious injury or death.
Switches FEATURES AND CONTROLS Differential Switch Use the differential switch to lock and unlock the rear differential. Locked Differential: Operate the vehicle with the switch in the locked position in most conditions. Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns. Operate with an unlocked differential only as needed to protect smooth, level surfaces from tire damage.
FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle. Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation.
Brake Lever FEATURES AND CONTROLS WARNING Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle. Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.
FEATURES AND CONTROLS Master Cylinder/Brake Fluid WARNING An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill. Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air.
Parking Brake FEATURES AND CONTROLS Locking the Parking Brake 1. Place the transmission in PARK. 2. Squeeze and release the brake lever two or three times, then squeeze and hold. 3. Push the parking brake lock forward to engage the lock. 4. Release the brake lever. 5. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position. WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire.
FEATURES AND CONTROLS Auxiliary Foot Brake WARNING Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill. Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
FEATURES AND CONTROLS Automatic Transmission Gear Selector Gear The transmission gear selector is Selector located on the right side of the vehicle. H: High Gear L: Low Gear N: Neutral R: Reverse P: Park To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear. NOTICE: Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
FEATURES AND CONTROLS Fuel Filter (500 EFI) The in-line fuel filter is located under the rubber service cover inside the front box. Have your dealer replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris. Do not attempt to clean the fuel filter. Fuel Tank Cap Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.
FEATURES AND CONTROLS All Wheel Drive System The All Wheel Drive system is controlled by the 4X4 switch. ADC 4X4 Mode When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or 4X4 incline. Always move the 4X4 Switch switch to ADC 4X4 before ascending or descending a hill. See page 39. 4X4 Mode When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.
FEATURES AND CONTROLS All Wheel Drive System Engaging 4X4 The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 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.
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
FEATURES AND CONTROLS Passenger Seat Always make sure the passenger seat lock-out is functioning properly before operating with a passenger. Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always return the seat to the 1-up position for single-rider operation. Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger. Seat Conversion 1. 2. 3. 4. Make sure the cargo box dump lever is securely latched.
Passenger Seat FEATURES AND CONTROLS Seat Conversion 5. Lift the adjustment latch at the top of the passenger backrest. Raise the backrest to the desired position. Release the latch, making sure it locks into one of the three operating positions. Tip: The backrest must be moved out of the lowest position before it can be secured in the upright position. The lowest position is for seat storage only. Do not leave the backrest in the lowest position.
FEATURES AND CONTROLS Instrument Cluster Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph. Refer to page 28 for additional information.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds 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 ATV to your Polaris dealer for proper diagnosis. 1.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Standard Modes Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 28. The transmission cannot be in reverse when using this feature. Odometer Mode The odometer records the miles traveled by the ATV. Trip Meter Mode The trip meter records the miles traveled by the ATV on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode. To enter the diagnostics mode: 1. Turn the key switch off and wait 10 seconds. 2. Lock the parking brake. 3. Place the transmission in neutral. 4. Hold the mode/reverse override button and turn the key switch on.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Battery Voltage Screen View this screen to check battery voltage level. Tachometer Screen View the tachometer to check engine speed. 4X4 Diagnostic Screen The gauge indicates whether or not current is flowing through the all wheel drive coil. This screen is for informational purposes only. Please see your dealer for all major repairs.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Diagnostic Mode Programmable service interval To enable or disable the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3. Press and hold the mode button for about 7 seconds, until either ON or OFF appears in the Rider Information Center, depending on your preference. To reset the service interval: 1. Enter the diagnostic mode. 2. Toggle to the service interval screen. 3.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. See page 49 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module. 1. Place the transmission in PARK. Stop the engine. Turn the key switch to the ON position. 2. Turn the key switch off and on three times in less than five seconds.
FEATURES AND CONTROLS Instrument Cluster Rider Information Center Downloading Codes Blink Code 12 22 22 22 25 31 31 36 36 37 37 41 41 42 42 44 45 46 47 47 51 51 52 52 55 55 56 56 58 58 59 59 63 63 72 73 73 74 74 61 Failure Description BEGIN SEQUENCE Throttle Position Sensor Low Throttle Position Sensor High Throttle Position Sensor Out of Adjustment Gear Sensor Signal System Voltage Low System Voltage High Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground Ignition Coil A Prim/Sec Ci
OPERATION WARNING Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual. Break-In Period The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline.
Break-In Period OPERATION Engine and Drivetrain Break-in 1. Fill the fuel tank with gasoline. See page 36. Always exercise extreme caution whenever handling gasoline. 2. Check the engine oil level on the dipstick. See page 80. Add oil if necessary to maintain the level between the safe and add marks. 3. Drive slowly at first. Select an open area that allows room to familiarize yourself with vehicle operation and handling. 4. Vary the throttle positions. Do not operate at sustained idle. 5.
OPERATION Pre-Ride Checklist Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
Safe Operation Practices OPERATION 1. Complete the recommended safety training before operating this vehicle. See page 7. 2. Do not allow anyone under 16 years of age to operate this vehicle. Do not allow anyone with cognitive or physical disabilities to operate this vehicle. 3. Engine exhaust fumes are poisonous. Never start the engine or let it run in an enclosed area. 4. Before operating, learn how to use the auxiliary brake for emergency situations (if service brakes become inoperable). 5.
OPERATION Know Your Riding Area/Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off-road vehicle in your area. Respect the environment in which you ride. Find out where the designated riding areas are by contacting your Polaris dealer, a local riding club or local officials. Help keep our trails open for recreational vehicle use. As an off-road enthusiast, you represent the sport and can set a good example (or a poor example) for others to follow.
Starting the Engine OPERATION 1. Position the vehicle on a level surface outdoors or in a well-ventilated area. 2. Place the transmission in PARK. 3. Lock the parking brake. Tip: The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged. 4. Sit on the vehicle and move the engine stop switch to RUN. Tip: Do not press the throttle while starting the engine. 5. Turn the ignition key past the ON position to engage the starter.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 56 Wear protective riding gear. See page 8. Perform the pre-ride inspection. See page 52. Place the transmission in PARK. Lock the parking brake. Mount the vehicle from the left side. Sit upright with both feet on the footrests and both hands on the handlebars. Start the engine and allow it to warm up. Shift the transmission into gear. Check your surroundings and determine your path of travel. Release the parking brake.
Turning the Vehicle OPERATION Both rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly. 1. Slow down. 2. Never turn quickly when carrying a passenger or cargo. 3. Steer in the direction of the turn. 4. Keep both feet on the footrests. 5.
OPERATION Driving with a Passenger 1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. 2. Do not carry a passenger until you have at least two hours of driving experience with this vehicle. 3. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 8. 4. Perform the pre-ride inspection. See page 52. 5.
Driving with a Passenger OPERATION 11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle. 12. Do not cross a hillside with a passenger on board. See page 62. 13. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.
OPERATION Driving on Slippery Surfaces Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions: 1. Do not operate on excessively rough, slippery or loose terrain. 2. Slow down when entering slippery areas. 3. Engage 4X4 before wheels begin to lose traction. NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning.
OPERATION Driving Uphill 15° Maximum Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions: 1. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 2. Never operate with the differential unlocked ( ) while operating on a hill or other irregular terrain. See pages 29 and 39. 3. Drive straight uphill. 4. Avoid steep hills (15° maximum). 5.
OPERATION Driving on a Sidehill (Sidehilling) Driving on a sidehill is not recommended. Improper procedure could cause loss of control or overturn. Avoid crossing the side of any hill unless absolutely necessary. If crossing a sidehill is unavoidable, follow these precautions: 1. Slow down. 2. Avoid crossing the side of a steep hill. 3. If operating in 2X4 mode, make sure the differential is locked. 4. Do not cross a hillside with a passenger on board.
OPERATION Driving Downhill 15° Maximum When driving downhill, follow these precautions: 1. Always check the terrain carefully before descending a hill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Always descend a hill with the transmission in forward gear. Do not descend a hill with the transmission in neutral. 4. Slow down. Never travel down a hill at high speed. 5. Drive straight downhill.
OPERATION Turning Around on a Hill (K-Turn) If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around. 8 ft. (2.
Turning Around on a Hill (K-Turn) OPERATION 1. Stop and lock the parking brake while keeping body weight uphill. 2. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39. 3. Leave the transmission in forward and shut off the engine. 4. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.
OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water: 1. Determine water depths and current before entering water. 2. Choose a crossing where Maximum Depth both banks have gradual inclines. 3. Avoid operating through deep or fast-flowing water. NOTICE: Major engine damage can result if the vehicle is not thoroughly inspected after operation in water.
Driving Over Obstacles OPERATION 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. Never attempt to operate over large obstacles, such as rocks or fallen trees. 5.
OPERATION Driving in Reverse Follow these precautions when operating in reverse: 1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view. 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. 7. Do not use the override switch unless additional wheel speed is required for vehicle movement.
Parking on an Incline OPERATION Avoid parking on an incline if possible. If it's unavoidable, follow these precautions: 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always block the rear wheels on the downhill side.
OPERATION Hauling Cargo WARNING Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo: Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle.
Hauling Cargo OPERATION Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual. Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. 1. Always load the cargo box with the load as far forward as possible. 2. Do not obstruct the headlight beam with cargo. 3.
OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight. • The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity. • The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
Hauling Cargo OPERATION Dumping Cargo 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. Place the transmission in PARK. 3. Lock the parking brake. 4. Dismount the vehicle. 5. Lower the tailgate. WARNING! If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible. 6.
EMISSION CONTROL SYSTEMS Noise Emission Control System Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements. Operation on Public Lands in the U.S.A. Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C.
Periodic Maintenance Chart MAINTENANCE 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 144.
MAINTENANCE Periodic Maintenance Chart WARNING Improperly performing the procedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services. Maintenance Chart Key X E Q Perform these operations more often for vehicles subjected to severe use. Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.
Periodic Maintenance Chart Item Maintenance Interval X Brake pad wear Q Battery Remarks (whichever comes first) Hours Calendar X Air filter, E main element MAINTENANCE Miles (Km) - Weekly - Inspect; replace as needed 10 H Monthly 100 (160) Inspect periodically 20 H Monthly 200 (320) Check terminals; clean; test X Rear gearcase oil (if equipped) 25 H Monthly 250 (400) Inspect level; change yearly X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly X Demand dr
MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks (whichever comes first) Hours Calendar Miles (Km) Q Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines, filter, pump; replace lines every two years X Radiator (if applicable) 100 H 12 M 1000 (1600) Inspect; clean external surfaces X Cooling hoses (if applicable) 100 H 12 M 1000 (1600) Inspect for leaks X Engine mounts 100 H 12 M 1000 (16
MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Items not listed in the chart should be lubricated at the General Lubrication interval. The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.
MAINTENANCE Engine Oil Oil Recommendations Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See page 79. Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 133 for the part numbers of Polaris products. NOTICE: Mixing brands or using a non-recommended oil may cause serious engine damage.
Engine Oil MAINTENANCE Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. Tip: A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately. Dipstick Safe Range { 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for 20-30 seconds. Stop the engine. 3. Remove the dipstick.
MAINTENANCE Engine Oil Oil Level (800 EFI) Tip: Due to the dipstick entry angle into the crankcase, the oil level will read higher on the bottom side of the dipstick. Always read the level on the upper surface of the dipstick. 5. After reinstalling the dipstick, seat the lever lock. 82 Dipstick Safe Add Oil Safe Range { Access the oil dipstick and fill tube from the left side of the ATV. 1. Position the vehicle on a level surface. 2. Lift the lever lock to remove the dipstick.
Engine Oil MAINTENANCE Oil and Filter Change (500 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to idle for two to three minutes. 3. Stop the engine. 4. Clean the area around the drain plug. 5. Place a drain pan under the oil Screen Fitting tank. Drain 6. Remove the drain plug. Allow Plug the oil to drain completely. CAUTION!Hot oil can cause burns to skin.
MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) 12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it. 13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 14. 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. 15.
Engine Oil MAINTENANCE Oil and Filter Change (500 EFI) Oil Pump Priming This priming procedure must be Tank performed whenever the oil hose 2" connection between the oil tank and (5 cm) pump inlet has been disconnected. 1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of Clamp the oil tank vent fitting and the Pressure vent line's pressure relief slit. Relief Slit 2. Start the engine. Allow it to idle for 10-20 seconds. 3. Remove the vent line clamp.
MAINTENANCE Engine Oil Oil and Filter Change (800 EFI) Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil. 1. Position the vehicle on a level surface. 2. Start the engine. Allow it to warm up at idle for two to three minutes. 3. Stop the engine. Drain Plug Location 4. Clean the area around the drain plug. 5. Place a drain pan under the crankcase. 6. Remove the drain plug.
Engine Oil MAINTENANCE Oil and Filter Change (800 EFI) 9. Place shop towels beneath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it. 10. Using a clean dry cloth, clean the filter sealing surface on the crankcase. 11. 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. 12.
MAINTENANCE Transmission Oil Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 133 for the part numbers of Polaris products. The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel.
Transmission Oil MAINTENANCE Transmission Oil Change 1. Remove the fill plug. 2. Place a drain pan under the gearcase. 3. Remove the drain plug. Allow the oil to drain completely. 4. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. Drain (27-34 Nm). Plug 5. Add 32 oz. (948 ml) of the recommended oil. 6. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm). 7. Check for leaks. Dispose of used oil properly.
MAINTENANCE Front Gearcase (Demand Drive) Fluid Fluid Level 1. Position the vehicle on a level surface. 2. Remove the fill plug. Check the fluid level. 3. Add the recommended demand drive fluid as needed to bring the level to the bottom of the fill hole threads. 4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm). Fluid Change 1. 2. 3. 4. 5. 6. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the demand drive unit. Remove the drain plug.
MAINTENANCE Active Descent Control (ADC) Fluid Fluid Level 1. Open the front box cover and pull open the access door. 2. View the fluid level in the reservoir. If the level is below the minimum mark, remove the cap and add the recommended fluid. 3. Reinstall the cap securely. Secure the access door and box cover. 500 EFI Fluid Change ADC Fluid Reservoir 1. Position the vehicle on a level surface. Before performing the fluid change, allow 800 EFI the vehicle to sit for at least 30 minutes. 2.
MAINTENANCE Cooling System The engine coolant level is controlled, or maintained, by the recovery system. The recovery system components are the recovery bottle, the radiator filler neck, the radiator pressure cap and the connecting hose. As coolant operating temperature increases, the expanding (heated) excess coolant is forced out of the engine, past the pressure cap, and into the recovery bottle.
Cooling System MAINTENANCE Radiator Coolant To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water. Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed. CAUTION!Escaping steam can cause burns.
MAINTENANCE Brakes Hand Brake The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are selfadjusting. Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed.
Toe Alignment MAINTENANCE Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out. WARNING! Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer. 1. Position the vehicle on a level surface. 2. Place the handlebars in a Stand straight-ahead position. 3.
MAINTENANCE Steering Assembly The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle. Side Panel Removal 1. Remove the seat. 2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet. Pull the panel downward and rearward to remove it. 3.
MAINTENANCE Tires WARNING Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires. Refer to the specifications section beginning on page 134 for recommended tire type, size and pressure.
MAINTENANCE Tires Wheel Installation 1. Place the transmission in PARK. 2. Lock the parking brake. 3. Place the wheel on the hub with the valve stem toward the outside and rotation arrows on the tire pointing toward forward rotation. 4. Install the wheel nuts and finger-tighten them. 5. Lower the vehicle to the ground. 6. Torque the wheel nuts to specification. WARNING! Loose nuts could cause a tire to come off during operation, which could result in an accident or overturn.
Air Filter 1. Remove the seat. 2. Release the air box cover clips, and remove the air box cover. 3. Loosen the clamp and remove the filter. 4. Remove the fabric type pre-filter from the main filter. Wash the prefilter in soapy water, then rinse and let dry. 5. Reinstall the pre-filter over the main filter. Install a new main filter if needed. 6. Reinstall the filter into the air box and tighten the clamp. Do not over-tighten the clamp, as filter damage could occur. 7.
MAINTENANCE Breather Filter/Hose (500 EFI) The breather filter is on the hose that runs between the engine and air box. 1. Remove the left side panel. See page 96. 2. Remove the hose clamps from the filBreather Filter ter and pull the filter out of the hoses. 3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace a damaged or clogged filter. 4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed. 5.
Fuse Replacement If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Spare fuses are provided in a compartment on the top of the access door. 1. Open the front box cover and pull open the access door. 2. Remove the suspect fuse from the fuse panel. If the fuse is blown, install a new fuse with the same amperage. 3. Secure the access door. 4. Secure the box cover.
MAINTENANCE Lights Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses become dirty during normal operation. Clean headlights frequently and replace burned out headlamps promptly. Always make sure lights are adjusted properly for best visibility. Headlight Lamp Replacement When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.
MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward. Use the following procedure to make the adjustment. 25 ft. (7.6 m) 2" (5 cm) 1. Position the vehicle on a level surface with the headlight approximately 25 ft. (7.6 m) from a wall. Place the transmission in PARK. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall at the same height. 3. Start the engine.Turn the headlight switch to high beam. 4.
MAINTENANCE Lights Headlight Housing Replacement 1. Remove the two screws on the lower front corners of the headlight pod. 2. Lift the pod slightly while depressing the tabs at the rear of the pod. 3. Lift the pod cover and disconnect the speedometer harnesses from the speedometer. 4. Unplug the headlamp from the wiring harness. 5. Use a small screwdriver to remove the o-rings from the headlight mounting tabs. 6. Pull the headlight housing up to release it from the locking tabs. 7.
Lights MAINTENANCE Lower Headlamp Replacement 1. Turn the back of the headlight harness counterclockwise and pull the harness assembly away from the headlight assembly. 2. Remove the headlamp and install the new headlamp. 3. Reinstall the harness assembly into the headlight assembly. 4. Turn the headlight harness clockwise to secure the headlamp. Harness Taillight/Brakelight/Worklight (if equipped) Lamp Replacement 1. Open the tailgate. 2. Remove the two screws near the tailgate latch. 3.
MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 134 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. NOTICE: Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Plug Condition Torque Specification New Spark Plug 9-11 ft. lbs. (12-15 Nm) Previously Installed Spark Plug 17-20 ft. lbs.
Spark Plugs MAINTENANCE Spark Plug Inspection Normal Spark 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 flaky and white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect fuel. Wet Fouled Spark Plug The wet fouled insulator tip is black.
MAINTENANCE Vehicle Immersion 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 it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 1. Move the ATV to dry land or at the very least, to water below the footrests. 2. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 3. Remove the spark plug. 4.
Spark Arrestor MAINTENANCE WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. Never run the engine in an enclosed area. Remove any combustible materials from the area. Wear eye protection and leather work gloves. Do not stand behind or in front of the vehicle while purging. Never go under the vehicle while it's inclined. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot.
MAINTENANCE 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. The PVT system rotates at high speeds, creating large amounts of force on clutch components.
PVT System MAINTENANCE The basic operation of the Polaris PVT system is dependent on engine speed and vehicle torque requirements. As engine speed increases, the force exerted on the movable drive sheave by the flyweights also increases. This, in turn, increases the amount of pinch applied to the drive belt. Similarly, if the engine speed decreases, the amount of centrifugal force decreases, reducing the amount of belt pinch.
MAINTENANCE PVT System When To Use Low Range and High Range Condition Operating at speeds less than 7 MPH (11 km/h) Range to Use Low Towing heavy loads Low Operating in rough terrain (swamps, mountains, etc.) Low Operating at speeds greater than 7 MPH (11 km/h) High 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. Position the vehicle on a level surface. 2. Remove the drain plug.
Battery MAINTENANCE WARNING 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. WARNING Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can result from contact with skin, eyes or clothing. Antidote: External: Flush with water.
MAINTENANCE Battery Battery Removal 1. 2. 3. 4. 5. 6. Loosen the battery hold-down bolt. Remove the battery cover. On conventional batteries, remove the battery vent tube. Disconnect the black (negative) battery cable first. Disconnect the red (positive) battery cable last. Lift the battery out of the ATV. Be careful not to tip a conventional battery sideways, which could spill electrolyte.
Battery MAINTENANCE 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 117 before installing the battery. 1. Ensure that the battery is fully charged. 2. Place the battery in the battery holder. 3. With conventional batteries, install the battery vent tube (sealed batteries do not have a vent tube).
MAINTENANCE Battery 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. Tip: Power plug leads may need to be bent down so that the battery cover can be installed.
Battery MAINTENANCE Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 114. 2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr rating. Charge as needed to raise the specific gravity to 1.270 or greater. 3. Reinstall the battery. See page 115. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) Always verify battery condition before and 1-2 hours after the end of charging. Charge Time State of Charge Voltage Action (Using constant current charger @ standard amps specified on top of battery) 100% 12.8-13.0 volts None required 75%-100% 12.5-12.8 volts 50%-75% 25%-50% 12.0-12.5 volts 11.5-12.0 volts None, check at 3 mos.
Cleaning and Storage MAINTENANCE 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: High water pressure may damage components. Polaris recommends washing the vehicle by hand or with a garden hose, using mild soap. Certain products, including insect repellents and chemicals, will damage plastic surfaces. Do not allow these types of products to contact the vehicle.
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 If warning and safety labels are damaged, contact your Polaris dealer for free replacement.
Cleaning and Storage MAINTENANCE Chrome Wheel Care (if equipped) Proper maintenance will protect chrome wheels from corrosion, preserve wheel life and ensure a "like new" appearance for many years. Chrome wheels exposed to road salt (or salt in the air in coastal areas) are more susceptible to corrosion if not properly cleaned. Clean chrome wheels more often if they're exposed to salt or other corrosive elements. 1. Wash chrome wheels frequently. Use a mild detergent.
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 119. 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 recommended amount.
Cleaning and Storage MAINTENANCE Storage Tips Fluid Levels Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance Chart beginning on page 75. • Demand drive unit (front gearcase) • ADC fluid (ADC models) (change every two years) • Rear gearcase (if equipped) • Transmission • 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.
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 75. Battery Storage See pages 116-117 for storage and charging procedures. Storage Area/Covers Set the tire pressure and safely support the ATV with the tires slightly off the ground. Be sure the storage area is well ventilated. Cover the vehicle with a genuine Polaris cover. Do not use plastic or coated materials.
Transporting the ATV MAINTENANCE Follow these procedures when transporting the vehicle. 1. Stop the engine. 2. Place the transmission in PARK. 3. Lock the parking brake. 4. Always secure the seat in the 1-up position to prevent loss during transporting. 5. Secure the fuel cap and oil cap. 6. Always tie the frame of the ATV to the transporting unit securely with suitable straps or rope. Do not attach tie straps to the front A-arm bolt pockets. 7. Remove the key to prevent loss during transporting.
ADJUSTMENTS Camber and Caster The camber and caster are non-adjustable. Rear Spring The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counterclockwise to increase or decrease spring tension. Tip: Accessory springs are available through your Polaris dealer.
Handlebars ADJUSTMENTS The handlebars can be adjusted for rider preference. WARNING! Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control and serious injury or death. Follow the adjustment procedures exactly, or see your Polaris dealer for service. 1. Remove the upper headlight pod. 2. Loosen the four handlebar bolts. 3. Adjust the handlebar to the desired height.
ADJUSTMENTS Throttle Body/Idle RPM Idle RPM is preset by the manufacturer. If the engine idle speed is not satisfactory, please see your Polaris dealer for adjustment. Throttle Cable Freeplay Adjust throttle cable freeplay at the handlebar. 1. Locate the throttle cable adjuster at the handlebar. 2. Squeeze the end of the rubber boot and slide it far enough to expose the end of the inline cable adjuster. 3. Loosen the adjuster lock nut. 4. Rotate the boot to turn the adjuster until 1/16" to 1/8" (1.
Drive Belt Wear/Burn Possible Cause Driving onto a pickup or tall trailer in high range Starting out going up a steep incline Driving at low RPM or ground speed (3-7 MPH) Insufficient warm-up at low ambient temperatures TROUBLESHOOTING Solution Use low range during loading. Use low range or turn around using the K-turn (see page 64). Drive at a higher speed or use low range more frequently. See page 112. Warm the engine at least 5 minutes.
TROUBLESHOOTING Engine Doesn't Turn Over Possible Cause Low battery voltage Loose battery connections Loose solenoid connections Solution Recharge the battery to 12.
Engine Pings or Knocks Possible Cause Poor quality or low octane fuel Incorrect ignition timing Incorrect spark plug gap or heat range TROUBLESHOOTING Solution Replace with recommended fuel See your dealer Set gap to specs or replace plugs Engine Runs Irregularly, Stalls or Misfires Possible Cause Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Water present in fuel Low battery voltage Kinked or plugged fuel tank vent l
TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Kinked or plugged fuel vent line Water is present in fuel Fouled or defective spark plug(s) Worn or defective spark plug wires Incorrect spark plug gap or heat range Loose ignition connections Low battery voltage Incorrect fuel Clogged air filter Reverse speed limiter malfunction Electronic throttle control malfunction Other mechanical failure Overheated engine Solution Refuel, cycle key to ON position three times for 5 seconds each, t
POLARIS PRODUCTS Part Number 2870791 2876244 2876245 2873602 2873603 2876144 2871653 2872276 2870465 2876251 2871323 2871534 2871312 2871322 2871423 2871460 2871515 2871551 2871329 2872073 2872348 2871326 2870652 2872189 2871956 2859044 Description Engine Lubricant Fogging Oil (12 oz. Aerosol) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.) PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt./.
SPECIFICATIONS Sportsman X2 500 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System Ig
SPECIFICATIONS Sportsman X2 500 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.
SPECIFICATIONS Sportsman X2 800 EFI Maximum Weight Capacity Dry Weight Front Rack/Storage Box Capacity Rear Storage Box Capacity Receiver Hitch Tongue Capacity Hitch Towing Rating Unbraked Trailer Towing Capacity* Overall Length Overall Width Overall Height Wheelbase Ground Clearance Minimum Turning Radius Fuel Capacity Engine Oil Capacity Coolant Capacity Demand Drive Fluid Capacity Transmission Oil Capacity Engine Displacement Bore x Stroke Alternator Output Compression Ratio Fuel System Ignition System I
SPECIFICATIONS Sportsman X2 800 EFI Transmission Gear Reduction, Low Gear Reduction, Reverse Gear Reduction, High Drive Ratio, Front Tires/Pressure, Front Tires/Pressure, Rear Brakes, Front Brakes, Rear Brake, Auxiliary Brake, Parking Headlight Taillights Brake Light Instrument Cluster Automatic EBS (Engine Braking System) with E-Z Shift H/L/N/R/P 23.91:1 21.74:1 8.28:1 3.
WARRANTY LIMITED WARRANTY Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIMITED WARRANTY on all components of the Polaris All Terrain Vehicle (ATV) against defects in material or workmanship. Polaris also gives a one year limited warranty on the final drive chain for failure due to defects. This warranty covers the parts and labor charges for repair or replacement of defective parts which are covered by this warranty. This warranty begins on the date of purchase.
WARRANTY WARRANTY COVERAGE AND EXCLUSIONS: LIMITATIONS OF WARRANTIES AND REMEDIES The Polaris limited warranty excludes any failures that are not caused by a defect in material or workmanship. This warranty does not cover accidental damage, normal wear and tear, abuse or improper handling.
WARRANTY ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you if inconsistent with controlling state law.
Exported Vehicles WARRANTY EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries. Dealers may not give authorization for export. You should consult an authorized dealer to determine this vehicle's warranty or service bulletin coverage if you have any questions.
WARRANTY Exported Vehicles How to Get Service If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied. Notice If your vehicle is registered outside of the country where it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind.
U.S.A. EPA Emissions Limited Warranty WARRANTY This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited warranty is in addition to the Polaris standard limited warranty for this vehicle. Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in materials and workmanship that may keep it from meeting these requirements.
MAINTENANCE LOG Present this section of your manual to your dealer each time your vehicle is serviced. This will provide you and future owners with an accurate log of maintenance and services performed.
MAINTENANCE LOG DATE MILES (KM) OR HOURS TECHNICIAN SERVICE PERFORMED / COMMENTS 145
