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WARNING The engine exhaust from this product contains chemicals known 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 2006 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 Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Features and Controls . . . . . . . . . . . . . . . . . . . 38 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Emission Control Systems . . . . . . . . . . . . . . . 84 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 136 Troubleshooting . . . .
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KNOW YOUR VEHICLE As the operator of the vehicle, you are responsible for your personal safety, the safety of others (including your passenger), and the protection of our environment. Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures. 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.
SAFETY Safety Decals and Locations Warning decals have been placed on the ATV for your protection. Read and follow the instructions of the decals on the ATV carefully. If any of the decals depicted in this manual differ from the decals on your ATV, always read and follow the instructions of the decals on the ATV. If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
SAFETY Safety Decals and Locations General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR OPERATOR AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN ONE General PASSENGER Warning NEVER USE WITH DRUGS OR ALCOHOL NEVER operate: • without proper training or instruction • at speeds too fast for your skills, your passenger’s skills, or the conditions • on public roads - a collision can occur with another vehicle • with mor
SAFETY Safety Decals and Locations Passenger Safety Warning WARNING PASSENGER SAFETY to reduce the risk of SEVERE INJURY or DEATH NEVER CARRY A PASSENGER UNDER AGE 12 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 grasp hand holds.
SAFETY Safety Decals and Locations Tire Pressure/Load Warning WARNING IMPROPER TIRE PRESSURE OR OVERLOADING can cause loss of control resulting in SEVERE INJURY OR DEATH. Tire Pressure/Load Warning TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, OPERATOR, PASSENGER AND CARGO IS 1500 LBS. (680 kg). Reduce speed and allow greater distance for braking when carrying cargo.
SAFETY Safety Decals 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) Clutch Cover Warning WARNING NO STEP • Moving parts hazard under belt-clutch guard. To prevent serious injury, do not operate vehicle with guard removed. • Do not modify engine or clutch.
Safety Decals and Locations SAFETY Reverse Override Warning WARNING Pushing reverse override button may cause sudden increases in power and traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual. Box Warning WARNING Remove flammable material containers from box before filling. WARNING Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs.
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. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
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 Rider Safety WARNING Failure to follow the warnings 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.
Rider Safety SAFETY Safety Training 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 Rider Safety 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, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert warning indicates a potential hazard that may result in serious injury or death.
SAFETY Rider 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 manual and all labels carefully, and follow the operating procedures described. • Never operate an ATV without proper instruction. Take a training course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCoursesm.
SAFETY Rider Safety • Never operate an ATV without wearing an approved helmet that fits properly. Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. A passenger's helmet should have a rigid chin guard. • Never consume alcohol or drugs before or while operating an ATV. • Never operate at excessive speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions. • Never attempt jumps or other stunts.
Rider Safety SAFETY • Always follow proper procedures for going downhill and for braking on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Drive straight downhill. • Always follow proper procedures for crossing the side of a hill. Do not cross a hillside with a passenger on board.
SAFETY Rider Safety • Always check for obstacles or people behind the ATV before operating in reverse. Be aware that a passenger can obstruct your view. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles. • Always use the size and type of tires specified for your ATV, and always maintain proper tire pressure. • Never modify an ATV through improper installation or use of accessories. • Never exceed the stated load capacity for your ATV.
Rider Safety SAFETY Equipment Modifications We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the operator does not know how to operate the ATV properly in different situations and on different types of terrain. HOW TO AVOID THE HAZARD Beginning and inexperienced operators should complete the ATV RiderCoursesm offered by Polaris through the SVIA.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating with more than one passenger. WHAT CAN HAPPEN Passengers affect balance and steering and increase the risk of losing control, which can result in severe injury or death. HOW TO AVOID THE HAZARD Never operate the 2-up ATV with more than one passenger. WARNING POTENTIAL HAZARD Carrying a passenger in the cargo box.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating this ATV on public streets, roads or highways. WHAT CAN HAPPEN The ATV could collide with another vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways. WARNING POTENTIAL HAZARD Riding an ATV without wearing an approved helmet, eye protection and protective clothing.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating the ATV after consuming alcohol or drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected. Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death. HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts. Avoid exhibition driving. WARNING POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of an accident or equipment damage.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Removing hands from the handlebars or feet from the footrests during operation. WHAT CAN HAPPEN 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.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Failure to use extra caution when operating on excessively rough, slippery or loose terrain. WHAT CAN HAPPEN Operating on excessively rough, slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn. HOW TO AVOID THE HAZARD 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.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees. >15° WARNING POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss of control or overturn.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for traveling down hills as described in the owner's manual. See page 75. If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 49. Always check the terrain carefully before descending a hill.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly crossing hills and turning on hills. WHAT CAN HAPPEN Improperly crossing or turning on hills could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 76. Use extra caution when turning on any hill. Do not cross a hillside with a passenger on board. Avoid crossing the side of a steep hill.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Stalling, rolling backwards or improperly dismounting while climbing a hill. WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when climbing a hill. If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 49. If all forward speed is lost: Lean forward to keep body weight uphill. A passenger should also lean uphill. Apply the single lever brakes.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction and loss of control, which could lead to an accident or overturn. HOW TO AVOID THE HAZARD Avoid operating the ATV through deep or fast-flowing water.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or uneven tire pressure. WHAT CAN HAPPEN Use of improper tires, or operation of the ATV with improper or uneven tire pressure, could cause loss of control or accident. HOW TO AVOID THE HAZARD Always use the size and type of tires specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and on safety decals.
SAFETY Rider Safety WARNING POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause changes in vehicle handling, which could lead to loss of control or an accident. HOW TO AVOID THE HAZARD Never exceed the stated load capacity for this ATV. Cargo should be properly distributed and securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.
SAFETY Rider Safety WARNING Operating a damaged ATV can result in an accident with serious injury or death. 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. WARNING Safe operation of this rider-active vehicle requires good judgement and physical skills.
FEATURES AND CONTROLS Switches Headlight Switch Mode/Reverse Override Switch Worklight Switch (if equipped) AWD Switch Main Key Switch Engine Stop Switch WARNING Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open. Mode/Reverse Override Switch This vehicle is equipped with a reverse speed limiter system.To gain additional power while backing, depress the override switch.
Switches FEATURES AND CONTROLS Engine Stop Switch Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off. NOTE: OFF RUN OFF Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights. Main Key Switch Use the main key switch to start the engine. See page 63 for starting procedures.
FEATURES AND CONTROLS Throttle Lever WARNING Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death. Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise. 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 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. Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding.
FEATURES AND CONTROLS Master Cylinder/Brake Fluid Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear. NOTE: When checking the fluid level, the ATV must be on level ground with the handlebars straight. Master Cylinder Indicator Window If the fluid level is low add DOT 4 brake fluid only.
Parking Brake FEATURES AND CONTROLS WARNING Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating. 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.
FEATURES AND CONTROLS Auxiliary Foot Brake The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel single lever system. 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.
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 Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake. CAUTION Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage.
FEATURES AND CONTROLS Recoil Starter (500 EFI) If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 63, cranking the engine with the recoil starter instead of the main key switch. 1. Grasp the recoil starter rope handle tightly. 2. Pull slowly so you can feel the engine strokes. NOTE: Handle Recoil Starter The rope will be harder to pull when the engine is on a compression stroke.
FEATURES AND CONTROLS All Wheel Drive (AWD) System The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4 (center position), the ATV is in twowheel drive at all times. When the switch is on AWD (left position), AWD the ATV is in all wheel drive and Switch the AWD indicator light in the instrument cluster will be on. When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction.
FEATURES AND CONTROLS All Wheel Drive (AWD) System Engaging AWD The AWD switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable the AWD until the engine RPM is below 3100. Once enabled, the AWD remains enabled until the AWD switch is turned off. If the switch is turned off while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.
FEATURES AND CONTROLS Active Descent Control (ADC) System The ADC system (if equipped) allows engine braking to all four wheels when the vehicle descends a hill or incline. If your ATV is equipped with Active Descent Control, always engage AWD 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. NOTE: 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. 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 38 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. NOTE: 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 38. NOTE: 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. AWD Diagnostic Screen The gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD). 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 59 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 Failure Description 12 BEGIN SEQUENCE 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 51 Injector Circuit Malfunction - Cyl 1: Ope
OPERATION Fuel Safety WARNING 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.
OPERATION 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. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.
OPERATION Pre-Ride Checklist WARNING If a proper inspection is not done before each use, severe injury or death could result. Always inspect the vehicle before each use to ensure it's in proper operating condition.
OPERATION Starting the Engine WARNING Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area. 1. Position the vehicle on a level surface. 2. Place the transmission in PARK. 3. Lock the parking brake. NOTE: 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.
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 exceed the stated load capacity for this vehicle. 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.
Hauling Cargo OPERATION Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the safety decals. 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. Do not obstruct the headlight beam with cargo.
OPERATION Hauling Cargo Towing Loads Always attach a towed load to the hitch point. 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. CAUTION Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 6 3/4" (17 cm).
OPERATION Hauling Cargo 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.
OPERATION Driving Procedures 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 68 Wear protective riding gear. See page 12. Perform the pre-ride inspection. See page 62. 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.
OPERATION Turning the Vehicle Both rear wheels drive equally at all times, except when operating in TURF mode. 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. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest.
OPERATION Driving with a Passenger 1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles. 2. Make sure the passenger is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 12. 3. Perform the pre-ride inspection. See page 62. 4. Convert the seat for 2-up riding. See page 50. Make sure the passenger seat lock-out is functioning properly. 5. Lock the parking brake. 6.
Driving with a Passenger OPERATION 10. 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. 11. Do not cross a hillside with a passenger on board. See page 74. 12. 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. 13.
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. Slow down when entering slippery areas. 2. Engage AWD before wheels begin to lose traction. 3. Maintain a high level of alertness, reading the trail and avoiding quick, sharp turns, which can cause skids. 4. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.
OPERATION Driving Uphill 15° Maximum Whenever traveling uphill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 49. 2. Drive straight uphill. 3. Avoid steep hills (15° maximum). 4. Keep both feet on the footrests. 5. Shift body weight uphill. 6. Proceed at a steady rate of speed and throttle opening. 7. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle. 8.
OPERATION Driving on a Sidehill (Sidehilling) WARNING Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Do not cross a hillside with a passenger on board. Follow proper procedures as outlined in the owner's manual. Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions: 1.
OPERATION Driving Downhill 15° Maximum WARNING Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down. Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually. When driving downhill, follow these precautions: 1. If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 49. 2.
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. If your ATV is equipped with Active Descent Control, engage AWD. See page 49. 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. 5.
OPERATION Driving Through Water Maximum Depth 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 crossing. 2. Choose a crossing where both banks have gradual inclines. 3. Proceed slowly, avoiding rocks and obstacles. 4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.
Driving Through Water OPERATION After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 85. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings. CAUTION Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.
OPERATION Driving Over Obstacles 1. Be alert! Look ahead and learn to read the terrain you're traveling on. Be constantly alert for hazards such as logs, rocks and low hanging branches. 2. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution. 3. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.
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 Driving in Reverse WARNING Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly. Do not use the override switch unless additional power is required for vehicle movement. Use with caution. Avoid backing on inclines, and avoid turning at sharp angles.
Driving in Reverse OPERATION 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. NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the override button with caution as rearward vehicle speed is greatly increased.
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 154.
MAINTENANCE Periodic Maintenance Chart Maintenance Chart Key X Perform these operations more often for vehicles subjected to severe use. E Emission-related service (Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.) Q Have an authorized Polaris dealer perform these services. WARNING Improperly performing the procedures marked with a Q could result in component failure and lead to serious injury or death.
Periodic Maintenance Chart Item Maintenance Interval Recoil housing (if applicable) 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 - Weekly - Drain water as needed, check often if operating in wet conditions 10 H Monthly 100 (160) Inspect periodically 20 H Monthly 200 (320) Check terminals; clean; test X Demand drive fluid 25 H Monthly 250 (400) Inspect level; cha
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 85. Items not listed in the chart should be lubricated at the General Lubrication interval. NOTE: 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 Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 143 for the part numbers of Polaris products. Premium 4 possesses unsurpassed film strength over the widest possible temperature range.
Engine Oil MAINTENANCE Oil Level (500 EFI) Access the oil dipstick and fill tube from the left side of the ATV. NOTE: 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) 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. Wipe it dry with a clean cloth. 3. Reinstall the dipstick completely, but do not lock it. The dipstick must be inserted completely to keep the angle and depth of the stick consistent. 4. Remove the dipstick and check the oil level. Maintain the oil level in the safe range. Do not overfill.
MAINTENANCE Engine Oil Oil and Filter Change (500 EFI) CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. 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.
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) CAUTION Hot oil can cause serious burns to skin. Do not allow hot oil to contact skin. Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. 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.
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 85. 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 143 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 ADC Fluid Reservoir 800 EFI ADC Fluid Reservoir Fluid Change 1. Position the vehicle on a level surface.
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.
MAINTENANCE Cooling System 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. WARNING Escaping steam can cause severe 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.
MAINTENANCE Toe Alignment 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. 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. 1. Place the handlebars in a straight-ahead position. 2. Place stands in front of the vehicle, perpendicular to the rear tires. String 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. 3. Pull the panel downward and rearward to remove it. Step 1 Step 2 Step 3 Footwell Removal 1.
MAINTENANCE Tires Refer to the specifications section beginning on page 144 for recommended tire type, size and pressure. 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. Maintain proper tire pressure as described on the decal on your ATV and in the owner's manual. Always use original equipment size and type when replacing tires.
MAINTENANCE Tires Wheel Installation WARNING Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer. 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.
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. NOTE: MAINTENANCE Pre-Filter Main Filter Install a new main filter if needed. 6. Reinstall the filter into the air box and tighten the clamp.
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 106. 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 (800 EFI) MAINTENANCE If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. NOTE: 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 When servicing a halogen lamp, don't touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. WARNING Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality. Hot components can cause serious burns to skin. Allow lamps to cool before servicing. Headlight Lamp Replacement 1.
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 CAUTION Using non-recommended spark plugs can result in serious engine damage. Always use Polaris-recommended spark plugs. Refer to the specifications section beginning on page 144 for the recommended spark plug type and gap for your vehicle. Torque spark plugs to specification. 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. NOTE: 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 CAUTION 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. 1. If it's impossible to take your ATV to a dealer before starting it, follow the steps outlined below. 2. Move the ATV to dry land or at the very least, to water below the footrests. 3. Check the air box. If water is present, dry the air box and replace the filter with a new filter. 4.
MAINTENANCE Spark Arrestor WARNING Failure to heed the following warnings while servicing the spark arrestor could result in serious injury or death. The exhaust system can get extremely hot. Do not perform service on the spark arrestor while the system is hot. Allow components to cool sufficiently before proceeding. 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.
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.
MAINTENANCE Battery Your ATV may have either a sealed battery, which requires little maintenance, or a conventional battery. A sealed battery can be identified by its flat covers on the top of the battery. A conventional battery has six filler caps on the top of the battery. Conventional Battery Always keep battery terminals and connections free of corrosion. If cleaning is necessary, remove corrosion with a stiff wire brush. Wash with a solution of one tablespoon baking soda and one cup water.
MAINTENANCE Battery 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. Battery Removal 1. 2. 3. 4. 5. 6. Disconnect the battery hold-down strap. Remove the battery cover. On conventional batteries, remove the battery vent tube.
MAINTENANCE Battery Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 127 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. NOTE: NOTE: Power plug leads may need to be bent down so that the battery cover can be installed.
MAINTENANCE Battery Battery Charging (Conventional Battery) 1. Remove the battery from the vehicle to prevent damage from leaking or spilled electrolyte during charging. See page 124. 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 125. Make sure the positive terminal is toward the front of the vehicle.
MAINTENANCE Battery Battery Charging (Sealed Battery) NOTE: 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. CAUTION 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 decals. 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 NOTE: 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. NOTE: 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 CAUTION 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 129. 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 85. • 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 85. Battery Storage See pages 126-127 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.
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. NOTE: Accessory springs are available through your Polaris dealer.
ADJUSTMENTS Handlebars 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 possible serious personal 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.
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 76). Drive at a higher speed or use low range more frequently. See page 122. 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 Description 2872889 2871326 2870652 2872189 2872893 2871956 Engine Lubricant Fogging Oil (12 oz. Aerosol) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (qt./.95 l) Premium 4 Synthetic 0W-40 (4-Cycle) Engine Oil (gal./3.8 l) Gearcase / Transmission Lubricants Premium AGL Synthetic Gearcase Lubricant (qt./.95 l) Premium AGL Synthetic Gearcase Lube (gal./3.8 l) Active Descent Control (ADC) Fluid Premium ATV Angle Drive Fluid (8 oz./237 ml) Premium ATV Angle Drive Fluid (2.
SPECIFICATIONS Sportsman X2 500 EFI Gross Vehicle Weight Dry Weight 1500 lbs. (680 kg) 798 lbs. (362 kg) (base model) (weight of other models may vary) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack/Storage Box Capacity 400 lbs. (181 kg) Receiver Hitch Tongue Capacity 120 lbs. (55 kg) (Rear rack capacity and tongue weight not to exceed 400 lbs./181 kg) Hitch Towing Rating 1225 lbs. (557 kg) on level ground Unbraked Trailer Towing 1995 lbs. (905 kg) Capacity* Overall Length 93 in.
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) w/E-Z Shift H/L/N/R/P 23.91:1 21.74:1 10.57:1 3.
SPECIFICATIONS Sportsman X2 800 EFI Gross Vehicle Weight Dry Weight 1500 lbs. (680 kg) 839 lbs. (381 kg) (base model) (weight of other models may vary) Front Rack/Storage Box Capacity 90 lbs. (41 kg) Rear Rack/Storage Box Capacity 400 lbs. (181 kg) Receiver Hitch Tongue Capacity 150 lbs. (68 kg) (Rear rack capacity and tongue weight not to exceed 400 lbs./181 kg) Hitch Towing Rating 1500 lbs. (680 kg) on level ground Unbraked Trailer Towing 1995 lbs. (905 kg) Capacity* Overall Length 93 in.
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) w/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 155
INDEX H Hand Brake . . . . . . . . . . . . . . . . . . . 104 Handlebar Adjustment . . . . . . . . . . 137 Hauling Cargo. . . . . . . . . . . . . . . 64-67 Headlight Housing Replacement . . 114 Headlight Lamp Replacement . . . . 112 Headlight Switch. . . . . . . . . . . . . . . . 39 Helmet. . . . . . . . . . . . . . . . . . . . . . . . 12 High Beam Adjustment . . . . . . . . . 113 High Range Use . . . . . . . . . . . . . . . 122 Hub Tightening . . . . . . . . . . . . . . . . 107 I Idle RPM Adjustment . . .
INDEX A D Accessories . . . . . . . . . . . . . . . . . . 134 Active Descent Control Fluid . 100-101 Active Descent Control System. . . . 49 Age Restrictions. . . . . . . . . . . . . . . . 14 Air Filter . . . . . . . . . . . . . . . . . . . . 109 All Wheel Drive System . . . . . . . 47-48 Auxiliary Foot Brake . . . . . . . . . . . 104 AWD Switch . . . . . . . . . . . . . . . . . . 47 Demand Drive Capacities . . . . . . . . . 99 Demand Drive Fluid . . . . . . . . . . . . 100 Disengaging ADC . . . . . . .
INDEX S T Spark Plug Recommendations. . . . 116 Spark Plug Torque Specification . . 116 Spark Plugs . . . . . . . . . . . . . . . 116-117 Specifications. . . . . . . . . . . . . . 144-147 Spring Adjustment, Rear Shock . . 136 Starting the Engine . . . . . . . . . . . . . 63 Steering Assembly . . . . . . . . . . . . . 106 Storage . . . . . . . . . . . . . . . . . . . 129-134 Storage Tips . . . . . . . . . . . . . . . 132-134 Switches AWD Switch . . . . . . . . . . . . . . 47 Engine Stop Switch . . . . . .
