Polaris 500 HHO 2013, Sportsman Touring 500 HO 2013 Owner's Manual

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Owner's Manual

for Maintenance and Safety

Sportsman Touring

500 HO

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 1-800­342-3764 for assistance.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc., 2100 Hwy 55
Medina, MN 55340
Phone [phone]
Part No. 9923799 Rev 01
Printed in USA

Improper vehicle use can result in SEVERE INJURY or DEATH.

READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

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

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 passenger seat is securely in place

THE OPERATOR MUST ALWAYS:

use proper riding techniques to avoid vehicle overturns on hills
and rough terrain and in turns

avoid paved surfaces - pavement may seriously affect handling
and control

reduce speed and use extra caution at all times when carrying a
passenger - dismount passenger when conditions require

make sure passenger reads and understands this label and
passenger safety label

NEVER operate:

*9923799 *

WARNING

1

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polarisindustries.com for the latest news, new product
introductions, upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and
recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• Low emission vehicles (LEVs)
We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Your manual
contains instructions for minor maintenance, but information about
major repairs is outlined in the POLARIS Service Manual and should be
performed only by a factory certified Master Service Dealer® (MSD)
technician.

Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

2

POLARIS and SPORTSMAN are registered trademarks of POLARIS Industries Inc.
Copyright 2012 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. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.

Printed in U.S.A.
2013 SPORTSMAN Touring 500 HO Owner’s Manual
P/N 9923799

3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Emission Control Systems . . . . . . . . . . . . . . . 66

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 120

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 124

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 126

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4

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.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.

5

INTRODUCTION

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. Understand all safety warnings, precautions and
operating procedures before operating a POLARIS ATV. Keep this manual
with the ATV.

• Never operate an ATV without proper instruction. Take a training course.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.

• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration lev­els of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was con-

trolled as indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on

many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

WARNING

6

INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the
spaces provided. Remove the spare key and store it in a safe place. An
ignition key can be duplicated only by ordering a POLARIS key blank
(using your key number) and mating it with one of your existing keys.
The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

####

Engine Serial Number

Key Number

VIN

(front or rear frame)

7

SAFETY

Safety Training

ATV safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding the ATV to
take a training course.

If you purchased a new POLARIS ATV in the United States, your dealer
provided information about the authorized ATV RiderCourse

sm

that is
available to you and your eligible family members. This training is
included in the purchase price of your ATV. You were also provided
with printed materials that explain safe operating procedures. You
should review this information on a regular basis.

If you purchased a used POLARIS ATV in the United States, you can
enroll in the ATV RiderCourse

sm

for a fee. Call ATV Enrollment

Express at [phone] or visit www.atvsafety.org.
If you purchased a POLARIS ATV outside the United States, please

contact your dealer or local law enforcement agencies for information
about safety training.

A POLARIS ATV is an off-road vehicle. Familiarize yourself with all
laws and regulations concerning the operation of this vehicle in your
area.

We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your vehi­cle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800­638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
POLARIS at 1-800-342-3764.

8

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

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.

Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

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.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Rid­ing pants with kneepads and a jersey with shoulder pads provide the best
protection.

Equipment Modifications

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.

The warranty on your POLARIS ATV is terminated if any equipment
has been added to the vehicle, or if any modifications have been made to
the vehicle, that increase its speed or power.

The addition of certain accessories, including (but not limited to) mow­ers, blades, tires, sprayers, or large racks, may change the handling char­acteristics of the vehicle. Use only POLARIS-approved accessories, and
familiarize yourself with their function and effect on the vehicle.

10

SAFETY

Safety Warnings

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. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.

Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.

Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age. Never allow anyone under 12 years of age to ride as a
passenger on this 2-up ATV.

Even though a child may be within the recommended age group for operating
some ATVs, he/she may not have the skills, abilities, or judgment needed to
operate or ride on this ATV safely and could be susceptible to accident or injury.

WARNING

11

SAFETY

Safety Warnings

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.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

• Turn the fuel valve off whenever the vehicle is stored or parked.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.

Failure to Inspect Before Operating

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.

Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.

12

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.

Carrying More Than One
Passenger

Carrying more than one passenger greatly
reduces the operator's ability to balance and
control the ATV, which may result in an
accident or overturn.

Never carry more than one passenger on this
2-up ATV.

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or
drugs could adversely affect operator
judgment, reaction time, balance and
perception.

Never consume alcohol or drugs before or
while operating an ATV.

13

SAFETY

Safety Warnings

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.

Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.

Operating on Public Roads

Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.

Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.

Operating at Excessive
Speeds

Operating the ATV at excessive
speeds increases the operator's risk
of losing control.

Never operate at excessive speeds.
Travel at speeds appropriate for
your skills, your passenger's skills,
and operating conditions.

14

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. 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.

Turning Improperly

Turning improperly could cause loss of
traction, loss of control, accident or
overturn.

Always follow proper procedures for
turning as described in the owner's
manual.

Practice turning at slow speeds before
attempting to turn at faster speeds.

Never turn at excessive speed.

Jumps and Stunts

Attempting wheelies, jumps and other
stunts increases the risk of an accident or
overturn.

Never attempt wheelies, jumps, or other
stunts. Avoid exhibition driving.

15

SAFETY

Safety Warnings

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 54.

Descending Hills Improperly

Improperly descending a hill could cause loss of
control or overturn.

Always follow proper procedures for traveling
down hills as described in the owner's manual.
See page 58.

Crossing Hillsides

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 hillside is unavoidable, always
follow proper procedures as described in the
owner's manual. See page 55.

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 56.

16

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.

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.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 56.

If the ATV begins rolling backwards:

• Keep operator and passenger body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards.

• Apply the single-lever brake gradually.

• When fully stopped, apply the foot brake as well, and then lock the parking
brake.

• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.

• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 56.

Operating on Steep Hills

Operating on excessively steep hills could
cause an overturn.

Never operate on hills too steep for the ATV or
for your abilities. Never operate the ATV on
hills steeper than 15 degrees.

+15°

17

SAFETY

Safety Warnings

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.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating
on unfamiliar terrain could result in an
accident or overturn.

Unfamiliar terrain may contain hidden rocks,
bumps, or holes that could cause loss of
control or overturn.

Travel slowly and use extra caution when
operating on unfamiliar terrain. Always be
alert to changing terrain conditions.

Operating Improperly in
Reverse

Improperly operating in reverse could result
in a collision with an obstacle or person.
Always follow proper operating procedures
as outlined in this manual. See page 61.

Before shifting into reverse gear, always
check for obstacles or people behind the ATV.
When it's safe to proceed, back slowly.

18

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. Avoid operating over large
obstacles such as rocks and fallen trees. If
unavoidable, use extreme caution and
always follow proper operating procedures
as outlined in this manual. See page 60.

Skidding or Sliding

Skidding or sliding can cause loss of control
or overturn (if tires regain traction
unexpectedly).

On slippery surfaces such as ice or loose
gravel, travel slowly and use extra caution
to reduce the chance of skidding or sliding.
Do not operate on excessively slippery
surfaces.

19

SAFETY

Safety Warnings

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

59):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or

stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving. The friction will help dry
out the pads.

Improper Cargo Loading

Overloading the ATV or carrying/towing
cargo improperly may cause changes in
handling, which could cause loss of control
or an accident.

• 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.

• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.

(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).

• NEVER exceed 50 MPH (80 km/h) while carrying a passenger.

• Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer.

• Always follow the instructions in the owner's manual for operating with a

passenger. See page 50.

20

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 unless you have independently veri­fied that the ice is sufficiently thick to sup­port the weight and moving force of the
ATV, you and your cargo, together with any
other vehicles in your party. Variances in
snow depth and/or water currents may
result in uneven ice thickness. Always
check with local authorities and residents
to confirm ice conditions and thickness
over your entire route. ATV operators
assume all risk associated with ice condi­tions on frozen bodies 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. Use caution
and drive at reduced speeds in conditions of reduced visibility such as fog, rain
and darkness. Clean headlights frequently and replace burned out headlamps
promptly.

21

SAFETY

Safety Warnings

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. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control. Never secure a
passenger to the vehicle or to the operator with a belt, rope or similar device.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the ATV

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.

22

SAFETY

Safety Labels 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 an informational or graphic label becomes illegible or comes off, con­tact your POLARIS dealer to purchase a replacement. Replacement
safety labels are provided by POLARIS at no charge. The part number is
printed on the label.

Passenger Warning/Discretionary 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 grasp hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and
protective gear

• securely grasp hand holds and
plant feet firmly on footrests while
seated in the passenger seat

• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require.

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees 15°. To
prevent overturn on hilly terrain, use throttle and brakes gradually.

• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.

7175845

Age 16

Warning

General

Warning

Passenger Warning

Discretionary Warning

23

SAFETY

Safety Labels and Locations

General 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 passenger seat is securely in place
THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid overturns on hills and rough terrain and

in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger -

dismount passenger when conditions require

• make sure passenger reads and understands this label and passenger safety

label
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7175844

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases the chances of
severe injury or death to both operator and passenger.

NEVER operate this ATV if you are under age 16.

7175375

24

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: 485 lbs. (220 kg)

7175642

Hitch Capacity Label

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND
HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)

7174159

Clutch Cover

Warning

Rack

Warning

Rack

Warning

Tire Pressure/Load

Warning

Hitch

Capacity

25

SAFETY

Safety Labels and Locations

Rack Warning

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 Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

7172572

Clutch Cover Warning

WARNING

• Moving parts hazard under belt-clutch guard. To prevent serious injury, do not
operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible
imbalance, and excessive engine RPM, which can result in serious injury or
death.

NO STEP

7172563

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

26

FEATURES AND CONTROLS

Switches

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. Always release the
throttle before activating the override switch.

The override switch is also used to toggle through the modes of the rider
information center. See page 36.

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

AWD

Switch

Choke

27

FEATURES AND CONTROLS

Switches

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.

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 47.

AWD Switch

Use the AWD switch to engage 4X4 or 2X4. See page 35.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the
lights from high beam to low beam. The key must be in the ON position
and the engine stop switch must be in the RUN position.

OFF OFFRUN

28

FEATURES AND CONTROLS

Throttle Lever

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. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.

Modifications to the throttle release switch could result in failure to perform as
designed, which could result in an accident. Do not attempt to modify the throttle
release switch or replace it with any after market throttle mechanisms. Always
ensure that the throttle cable is installed and properly routed to the throttle
release switch.

Engine speed and vehicle move­ment are controlled by pressing the
throttle lever. The throttle lever is
spring loaded. Engine speed returns
to idle when the lever is released.

This ATV is equipped with a throt­tle release switch, which is
designed to reduce the risk of a fro­zen or stuck throttle. If the throttle
cable should stick in an open posi­tion when the operator releases the throttle lever, the engine will stop,
and power to the rear wheels will cease.

WARNING

29

FEATURES AND CONTROLS

Brake Lever

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.

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. Contact your dealer for proper
diagnosis and repairs.

WARNING

30

FEATURES AND CONTROLS

Master Cylinder/Brake Fluid

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. The moisture causes the
boiling temperature of the brake fluid to drop, which can lead to early brake fade
and the possibility of brake failure, which could result in an accident. After
opening a bottle of brake fluid, always discard any unused portion.

Check the brake fluid in the master
cylinder before each ride.

1. Position the ATV on a level
surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window
on the top of the master cylin­der. The eye will appear dark
when the fluid level is full.
When fluid is low, the eye will
be clear.

4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

WARNING

Master Cylinder

Indicator

Window

31

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in
PAR K.

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. Always check to be sure the parking brake is disengaged
before operating.

The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.

32

FEATURES AND CONTROLS

Auxiliary Foot Brake

Never back down a hill. Applying the auxiliary brake when backing down a hill
may cause rear tipover, which could result in serious injury or death.

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.

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. Since this is a rear brake only, it will not be as effective as the all­wheel single lever system.

The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.

If the rear wheels slide while using
the auxiliary brake, reduce brake
pedal pressure to brake the rear
wheels without skidding.

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat. Maintain the fluid level between
the maximum and minimum marks.

WARNING

Auxiliary Foot Brake

33

FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector is
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.

Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at
less than seven miles per hour for extended periods and when operating
uphill at a slow speed.

Choke

The choke assists in starting a cold
engine. Refer to the engine starting
procedure on page 47 for correct choke
and throttle settings during starting.

Fuel Valve

The fuel valve is located in the left
front wheel well.

OFF: For vehicle storage and when
transporting.

ON: For normal operation.

Gear

Selector

OFF

ON

Fuel

Valve

34

FEATURES AND CONTROLS

Passenger Seat

Always make sure the passenger
seat is installed and securely
latched before operating with a
passenger. Test the seat latch by
attempting to pull the seat
upward. If the lock-out is not

working properly, do not allow a
passenger to ride the vehicle.

See your POLARIS dealer for service.
To remove the seat, pull the latch loop at the rear of the seat. Pull the

seat upward to remove it from the vehicle.
To reinstall the seat, make sure the rubber feet at the base of the seat are

positioned in the rear rack. Press down firmly on the seat pad until the
latch clicks.

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100
hours of operation, or annually. Do not attempt to clean the fuel filter.

Fuel Tank Cap

This vehicle is equipped with a
digital fuel gauge that will indi­cate a low fuel condition. Refuel
when the gauge indicates a low
fuel condition.

Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.

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 fuel with ethanol content
greater than 10 percent, such as
E-85 fuel.

Latch

Fuel

Tank

Cap

35

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, the
ATV is in two-wheel drive at all
times. When the switch is on
AWD, the ATV is in all wheel
drive and 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. When the rear wheels regain traction, the demand drive unit will
automatically disengage.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging AWD

The AWD switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable the AWD until
the engine RPM is below 3100. Once enabled, the AWD remains
enabled until the AWD switch is turned off. If the switch is turned off
while the demand drive unit is moving, it will not disengage until the
rear wheels regain traction.

Engage the AWD switch before getting into conditions where front
wheel drive may be needed. If the rear wheels are spinning, release the
throttle before switching to AWD.

AWD

Switch

36

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 (11-14 km/h). Refer to page 26
for additional information.

NOTICE: High water pressure may damage ATV components. Wash the ATV

by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will

damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.

Rider

Information

Center

Speedometer

Needle

Speedometer

37

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. Gear Indicator - This
indicator displays gear
shifter position:
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park

2. AWD Indicator - This

indicator illuminates
when the AWD switch
is in the AWD
position.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and Over Voltage - This warning usually indicates

that the ATV is operating at an RPM too low to keep the battery
charged. It may also occur when the engine is at idle and high elec­trical load (lights, cooling fan, accessories) is applied. Drive at a
higher RPM or recharge the battery to clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments will flash, FUEL will display in the LCD,
and the speedometer needle will blink. Refuel immediately.

8. Check Engine Warning Indicator - The word HOT displays if the

engine overheats. Do not operate the ATV if this warning appears.
Serious engine damage could result.

9. Mode Indicator

1

2

345

6

7

9

8

38

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 26. 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.
Press and hold the mode button (override button) until the total changes
to 0. In the Rider Information Center, the trip meter display contains a
decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

This mode logs the total hours the engine has been in operation.

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM
from day to day may be normal because of changes in humidity, temper­ature and elevation.

39

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.

Release the switch as soon as the display is activated.

5. Use the mode button to toggle through the diagnostic screens.

40

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.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the
gear switch input of the gauge. This screen is for informational purposes
only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 41.

The service interval is programmed at 50 hours at the factory.

41

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. Press and hold the mode button for 2-3 seconds, until the wrench

icon flashes. Release the button.

4. Press and release the mode button once to advance the setting by

one hour. Press and hold the mode button to advance the hours
quickly.

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

6. When the desired setting is displayed, wait until the wrench icon

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display
either standard or metric units of measurement.

1. Enter the diagnostic mode.

2. Toggle to the screen that displays either kilometers (KM) or miles

(MP).

3. Press and hold the mode button until the letters flash, then press and

release the button once. When the display stops flashing, the mode
has been set.

42

OPERATION

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 20 hours of
operation. 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.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts and drive components. Do not
operate at full throttle or high speeds during the first three hours of
use.

WARNING

43

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 34. Always exercise
extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 72. 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 famil-

iarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

5. Perform regular checks on fluid levels, controls and areas outlined

on the daily pre-ride inspection checklist. See page 44.

6. Pull only light loads.

7. Change both the oil and the filter at 25 hours.

8. Check fluid levels of transmission and all gearcases after the first 25

hours of operation and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life
and better performance. Break in the clutches and belt by operating at
slower speeds during the break-in period as recommended. Pull only
light loads. Avoid aggressive acceleration and high speed operation dur­ing the break-in period.

If a belt fails, always clean away all debris when replacing the belt.

44

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.

Item Remarks Page

Passenger seat latch Ensure latch is secure 34

Brake system/lever travel Ensure proper operation 29

84

Brake fluid Ensure proper level 30

Auxiliary brake Ensure proper operation 32

Front suspension Inspect, lubricate if necessary 71

Rear suspension Inspect, lubricate if necessary 71

Steering Ensure free operation -

Tires Inspect condition and pressure 87

Wheels/fasteners Inspect, ensure fastener tightness 87

88

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 34

72

Coolant level (if applicable) Ensure proper level 82

83

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 28

101

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 27

Air filter, pre-filter Inspect, clean 89

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply POLARIS

dielectric grease when lamp is
replaced

27
92

Brake light/taillight Check operation, apply POLARIS

dielectric grease when lamp is
replaced

95

Riding gear Wear approved helmet, goggles, and

protective clothing

8

45

OPERATION

Safe Operation Practices

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 emer-

gency situations (if service brakes become inoperable).

5. Operate this vehicle off-road only. Never operate the vehicle on

pavement or on any public street, road or highway, including dirt
and gravel roads.

6. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights fre­quently and replace burned out headlamps promptly.

7. Drive in a manner appropriate for your skills, your passenger’s

skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your
hands from the handlebars while operating, and always keep both
feet on the footrests.

8. Never consume alcohol or drugs before or while operating an ATV.

9. Always use the size and type of tires specified for your vehicle.

Always maintain proper tire pressure.

10. Never operate a damaged ATV. After any overturn or accident, have

a qualified service dealer inspect the entire machine for possible
damage.

11. Never operate the ATV on a frozen body of water unless you have

independently verified that the ice is sufficiently thick to support the
weight and moving force of the ATV, you and your cargo, together
with any other vehicles in your party.

12. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

46

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. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

47

OPERATION

Starting the Engine

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. Turn the fuel valve on.

5. Sit on the vehicle.

6. Do not use the choke if starting a warm engine. Excessive use of the

choke can cause the spark plug to become wet fouled.

7. If the engine is cold, pull the

choke knob out until it stops.

Tip: The variable choke is fully on

when the knob is pulled com­pletely out. The choke is off when
the knob is pushed completely in.
The choke can be adjusted gradu­ally, depending on how much
choke is needed for starting. Be
sure the choke is off during opera­tion, as excess fuel washing into
the engine oil will increase wear
on engine components.

8. If the knob doesn't stay where

positioned, increase the ten­sion by rotating the tension
adjusting nut clockwise.

9. Move the engine stop switch to RUN.

10. Do not press the throttle while starting the engine.

Tens ion

Adjusting Nut

48

OPERATION

Starting the Engine

11. Turn the ignition key past the ON position to engage the starter.
Activate the starter for a maximum of five seconds, releasing the
key when the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

damage. Allow the engine to warm up for several minutes before
operating the vehicle.

12. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.

Tip: If a warm engine has cooled to a point where it does not readily start, inter-

mittent use of the choke button (pulled half way out) may be necessary. If
the engine is over-choked when warm, depress the throttle lever fully while
cranking to aid in starting. Release the throttle lever immediately after the
engine starts. If the engine does not start and all conditions are favorable,
change the spark plug and try again.

13. If the engine slows or stops, position the choke knob half way in to
allow proper engine warm up. Vary the engine RPM slightly with
the throttle to aid in warm-up. When the engine idles smoothly,
push the choke completely in.

Cold Weather Operation

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

See your POLARIS dealer for engine heater kits, which provide quicker
warm-ups and easier starting in colder weather.

49

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 44.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

6. Sit upright with both feet on the footrests and both hands on the
handlebars.

7. Start the engine and allow it to warm up.

8. Shift the transmission into gear.

9. Check your surroundings and determine your path of travel.

10. Release the parking brake.

11. Slowly depress the throttle with your right thumb and begin driving.

12. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.

50

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, includ-

ing an approved helmet with a rigid chin guard. See page 8.

4. Perform the pre-ride inspec-

tion. See page 44.

5. Always make sure the pas-

senger seat is installed and
securely latched before
operating with a passenger.

6. Lock the parking brake.

7. Mount the vehicle from the

left side. After the operator
is seated, the passenger
should mount the vehicle
from the left side. Always
make sure the brake is
engaged to ensure the vehi­cle remains motionless
whenever a passenger
mounts or dismounts.

8. Allow a passenger to ride

only in the approved pas­senger seat.

9. Do not carry more than one passenger.

10. Slow down. Control may be more difficult with a passenger on

board. Allow more time and distance for braking.

51

OPERATION

Driving with a Passenger

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 55.

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.
Never secure a passenger to the vehicle or to the operator with a
belt, rope or similar device.

14. Make sure the passenger understands the importance of “active rid­ing.” When hill-climbing or performing maneuvers, a passenger
should shift body weight in the same manner in which the driver
shifts body weight. For example, the passenger should lean to the
inside of a turn along with the operator and should always lean
uphill when climbing and descending hills.

52

OPERATION

Turning the Vehicle

Your ATV is equipped with a
solid rear axle, which drives
both rear wheels equally at all
times. 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. This technique alters the balance of traction between
the rear wheels, allowing the turn to be made smoothly. The same
leaning technique should be used for turning in reverse.

6. Practice making turns at slow speeds before attempting to turn at
faster speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.

53

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 AWD before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if the AWD is engaged while

the wheels are spinning. Allow the rear wheels to stop spinning
before engaging AWD, or engage AWD before wheels begin to lose
traction.

4. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.

5. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.

Sideways

skid

Turn in

direction of

skid

54

OPERATION

Driving Uphill

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. Drive straight uphill.

2. Avoid steep hills (15° maximum).

3. Always check the terrain carefully before ascending any hill.

4. Never climb hills with excessively slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill. A passenger should also shift body weight
uphill.

7. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.

8. Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.

9. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.

15° Maximum

55

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. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.

4. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.

5. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!

56

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. (2.4 m)

57

OPERATION

Turning Around on a Hill (K-Turn)

1. Stop and lock the parking brake while keeping body weight uphill.

2. Leave the transmission in forward and shut off the engine.

3. 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. A passen-

ger should not remount until the vehicle returns to firm, level
ground.

4. Staying uphill of the vehicle, turn the handlebars full left.

5. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point­ing across the hill or slightly downward.

6. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill. A passenger should not remount until
the vehicle returns to firm, level ground.

7. Start the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.

58

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Always check the terrain carefully before descending a hill.

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. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.

6. Shift body weight uphill. A passenger should also shift body weight
uphill.

7. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss
of control.

15° Maximum

59

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

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. Perform the services outlined in
the maintenance chart. See page 67. The following areas need
special attention: engine oil, transmission oil, demand drive fluid and
all grease fittings

.

If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 102,
then see your dealer for service at the first opportunity.

4. After leaving water, test the brakes. Apply them lightly several

times while driving slowly. The friction will help dry out the pads.

If it’s unavoidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops.

Do not make sudden throttle changes.

Maximum Depth

60

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

1. Always check for obstacles before operating in a new area.

2. Look ahead and learn to read the terrain. Be constantly alert for haz­ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.

5. Always have a passenger dismount before operating over an obsta­cle that could cause a fall from the vehicle or vehicle tipover.

61

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. Use the override with caution as
rearward vehicle speed is greatly increased. Do not operate at wide
open throttle. Operate the throttle just enough to maintain a desired
speed.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine
damage.

62

OPERATION

Parking on an Incline

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.

5. Turn the fuel valve off.

63

OPERATION

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions when hauling cargo:

Never carry cargo on the rear rack 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. When
determining the weight you are adding to the vehicle, include the weight of the
operator, passenger, accessories, loads in the rack or box and the load on the
trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity.

CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on
the rear rack. When operating over rough or hilly terrain, reduce speed and
cargo to maintain stable driving conditions. Carrying loads on only one rack
increases the possibility of vehicle overturn.

CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high
on the racks raises the center of gravity of the vehicle and creates a less stable
operating condition.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create
unstable operating conditions, which could result in loss of control of the vehicle.

OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When
handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.

HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use
extreme caution when applying brakes with a loaded vehicle. Avoid terrain or
situations that may require backing downhill.

USE EXTREME CAUTION when operating with loads that extend over the rack
sides. Stability and maneuverability may be adversely affected, causing the
vehicle to overturn.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS.
NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34

kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 50 MPH
(80 km/h) while carrying a passenger.

The vehicle should never exceed 10 MPH (16 km/h) while towing a load on a
level surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing
loads in rough terrain, while cornering, or while ascending or descending a hill.

WARNING

64

OPERATION

Hauling Cargo

Never exceed the weight
capacities specified for your
ATV on warning labels and in
the specifications section of
this manual.

1. Cargo weight should be
evenly distributed (1/3 on
the front rack and 2/3 on
the rear rack) and mounted
as low as possible.

2. When operating over rough

or hilly terrain, reduce
speed and cargo weight to
maintain stable driving
conditions.

3. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above

75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).

4. NEVER exceed 50 MPH (80 km/h) while carrying a passenger.

5. Do not obstruct the headlight beam with cargo.

6. Slow down.

7. Use low forward gear when hauling or towing heavy cargo to

extend belt life.

8. Always operate the vehicle with extreme caution whenever hauling

or towing loads. Balance, handling, and control may be affected.

2/3

1/3

65

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.

NOTICE: 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 4" (10 cm). Never install
automotive accessories on your
POLARIS ATV. Always install
POLARIS-approved (or equivalent)
accessories designed for ATV use.

Maximum

4" (10 cm)

66

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 arrester that was tested and qualified to be in accor­dance with the USFS standard 5100-1c. Federal law requires that this spark arrester be
installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420.
Violations are subject to monetary penalties. Federal regulations can be viewed online at
www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

This engine is equipped with a closed crankcase system. Blow-by gases are forced back
to the combustion chamber by the intake system. All exhaust gases exit through the
exhaust system.

Exhaust Emission Control System

The emissions from the exhaust of this vehicle are
controlled by engine design, including factory-set
fuel delivery and ignition. The engine and related
components must be maintained at POLARIS
specifications to achieve optimal performance.

Engine idle speed is the only adjustment
POLARIS recommends that the operator perform.
Any other adjustments should be performed by an
authorized POLARIS dealer.

The emissions label is located on the right frame
tube.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European directives 97/24/EC and

2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic energy. People with

active or non-active implantable medical devices (such as heart monitoring or control­ling devices) should review the limitations of their device and the applicable electro­magnetic standards and directives that apply to this vehicle.

Emissions Label

67

MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,
most reliable condition. Inspection, adjustment and lubrication of
important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, use genuine
POLARIS parts available from your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on
page 135.

Service and adjustments are important for proper vehicle operation. If
you're not familiar with safe service and adjustment procedures, have a
qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average rid­ing conditions and an average vehicle speed of approximately 10 miles
per hour. Vehicles subjected to severe use must be inspected and ser­viced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

68

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

WARNING! Improperly performing the procedures marked with a “D” could

result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Symbol Description

 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)

D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering -

Pre-Ride

-

Make adjustments as
needed. See Pre-Ride
Checklist on page 44.

Front suspension - -

Rear suspension - -

Tires - -

Brake fluid level - -

Brake lever travel - -

Brake system - -

Passenger seat
latch

--

Wheels/fasteners - -

Frame fasteners - -

Engine oil level - -

EAir filter, pre-filter - Daily - Inspect; clean often; replace

as needed

 Air box sediment

tube

- Daily - Drain deposits when visible

Coolant
(if applicable)

- Daily - Check level daily, change
coolant every 2 years

Headlight/taillight - Daily - Check operation; apply

dielectric grease if replacing
lamps

69

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

EAir filter,

main element

- Weekly - Inspect; replace as needed

Recoil housing
(if applicable)

- Weekly - Drain water as needed,
check often if operating in wet
conditions

DBrake pad wear 10 H Monthly 100 (160) Inspect periodically

Battery 20 H Monthly 200 (320) Check terminals; clean; test

 Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change

 Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check

 Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check

 Transmission oil 25 H 1 M 250 (400) Break-in oil level check

EEngine breather

filter (if equipped)

25 H Monthly 250 (400) Inspect; clean if needed

 General

lubrication

50 H 3 M 500 (800) Lubricate all fittings, pivots,

cables, etc.

Carburetor float
bowl

50 H 6 M 500 (800) Drain bowl periodically and

prior to storage

Shift linkage 50 H 6 M 500 (800) Inspect, lubricate

D Steering 50 H 6 M 500 (800) Lubricate

 Front suspension 50 H 6 M 500 (800) Lubricate

 Rear suspension 50 H 6 M 500 (800) Lubricate

DEThrottle Cable/

Throttle Release
Switch

50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

DEChoke cable 50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

E Carburetor air

intake ducts/flange

50 H 6 M 500 (800) Inspect duct for proper seal-

ing/air leaks

Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as

needed

Cooling system
(if applicable)

50 H 6 M 1000 (1600) Inspect coolant strength

seasonally; pressure test
system yearly

 Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter

 Demand drive fluid 100 H 12 M 1000 (1600) Change fluid

 Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid

 Transmission oil 100 H 12 M 1000 (1600) Change fluid

70

MAINTENANCE

Periodic Maintenance Chart

 Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

DEValve clearance 100 H 12 M 1000 (1600) Inspect; adjust

DEFuel system/filter 100 H 12 M 1000 (1600) Check for leaks at tank cap,

lines, fuel valve, filter, pump,
carburetor; replace lines
every two years

 Radiator

(if applicable)

100 H 12 M 1000 (1600) Inspect; clean external

surfaces

 Cooling hoses

(if applicable)

100 H 12 M 1000 (1600) Inspect for leaks

 Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

DESpark plug 100 H 12 M 1000 (1600) Inspect; replace as needed

 Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,

security; apply dielectric
grease to connectors
subjected to water, mud, etc.

D Clutches (drive

and driven)

100 H 12 M 1000 (1600) Inspect; clean; replace worn

parts

D Front wheel

bearings

100 H 12 M 1000 (1600) Inspect; replace as needed

D Brake fluid 200 H 24 M 2000 (3200) Change every two years



D
E

Fuel filter 200 H 24 M 2000 (3200) Check for leaks around lines.

Replace every 2 years, more
often under
extreme conditions.

Spark arrester 300 H 36 M 3000 (4800) Clean out

D Toe adjustment - Inspect periodically; adjust

when parts are replaced

Headlight aim - Adjust as needed

71

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. 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.

Item Lube Capacity at

Fluid Change

Inspection Procedure

Engine Oil PS-4 PLUS

Performance
Synthetic 2W-50

2 qt. (1.9 l) See page 72.

Brake Fluid DOT 4 Only --- See page 30.

Transmission Oil AGL PLUS

Transmission Fluid

32 oz. (948 ml) See page 77.

Demand Drive
Fluid (Front
Gearcase)

Demand Drive
PLUS Fluid

9 oz. (265 ml) See page 79.

Front Prop Shaft
Yoke

POLARIS Pre­mium U-Joint Lube

--- Grease fittings (3 pumps
maximum) every 500 miles,
before long periods of stor­age, or after pressure wash­ing or submerging.

Front Prop Shaft Yoke

72

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.

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 126 for the part num­bers of POLARIS products.

NOTICE: Mixing brands or using a non-recommended oil may cause serious

engine damage. Always use the recommended oil. Never substitute
or mix oil brands.

73

MAINTENANCE

Engine Oil

Oil Level

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.

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. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

the oil level. Maintain the oil
level in the safe range. Do not
overfill.

6. Reinstall the dipstick securely.

Safe

Add Oil

{

Safe Range

Dipstick

74

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67.

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
tank.

6. Remove the drain plug. Allow
the oil to drain completely.

CAUTION! Hot oil can cause burns to
skin. Do not allow hot oil to contact skin.

7. Install a new sealing washer on
the drain plug. The sealing sur­faces on drain plug and crank­case should be clean and free of
burrs, nicks or scratches.

8. Reinstall the drain plug. Torque
to 14-17 ft. lbs. (19-23 Nm).

9. Disconnect the lower oil deliv­ery hose and remove the screen
fitting from the oil tank. Clean
the fitting.

Tip: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal

tape.

10. Reinstall the screen fitting and rotate the fitting clockwise a mini­mum of 2 1/2 turns into the tank threads. Continue to rotate the fit­ting until the nipple of the fitting aligns with the mark on the tank.

Tip: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34

Nm).

11. Reattach the oil line.

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

75

MAINTENANCE

Engine Oil

Oil and Filter Change

12. Place shop towels beneath the oil
filter. Using an oil filter wrench,
turn the filter counter-clockwise
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. Install the new filter and rotate it clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.

16. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank­case.

17. Reinstall the drain plug. The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or scratches.
Torque to 14 ft. lbs. (19 Nm).

18. Remove the dipstick.

19. Add two quarts (1.9 l) of recommended oil. If the sump is not
drained, add about 1 3/4 quarts (1.6 l) initially.

20. Reinstall the dipstick.

21. Place the transmission in PARK.

22. Lock the parking brake.

23. Prime the oil pump using the procedure on page 76. Then stop
the engine and inspect for leaks.

24. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.

25. Dispose of used filter and oil properly.

76

MAINTENANCE

Engine Oil

Oil and Filter Change

Oil Pump Priming

This priming procedure must be
performed whenever the oil hose
connection between the oil tank and
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
the oil tank vent fitting and the
vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and
ready for operation.

Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.

Clamp

Pressure

Relief Slit

Tank

2"

(5 cm)

77

MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 67. Maintain the
oil level at the bottom of the fill plug hole threads. POLARIS recom­mends the use of POLARIS AGL PLUS Transmission Fluid for this
transmission. See page 126 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.

The drain plug is located on the right side of the gearcase, on the right
side of the ATV, behind the wheel well.

Transmission Oil Level

1. Position the vehicle on a level
surface.

2. Remove the fill plug.

3. Check the oil level. Add the

recommended oil as needed.

4. Reinstall the fill plug. Torque

to 20-25 ft. lbs. (27-34 Nm).

Drain Plug

Fill Plug

Fill Plug

78

MAINTENANCE

Transmission Oil

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.
(27-34 Nm).

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.

Drain
Plug

79

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out­lined in the Periodic Maintenance Chart beginning on page 67. We rec­ommend the use of Demand Drive PLUS Fluid. Use of other fluids may
result in improper operation of components. See page 126 for the part
numbers of POLARIS products.

Maintain the fluid level at
the bottom of the fill hole
threads. See below for
capacity.

The fill plug is located on
the right side of the
demand drive unit. The
drain plug is located on the
bottom right side of the
unit.

Demand Drive Capacity

SPORTSMAN Touring 500 HO 9 oz. (265 ml)

Drain Plug

Fill
Plug

Fill Level

80

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. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Place a drain pan under the demand drive unit.

4. Remove the drain plug. Allow the fluid to drain completely.

5. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).

6. Add the recommended fluid. See page 79 for capacity. Maintain the
fluid level at the bottom of the fill hole threads.

7. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

8. Check for leaks.

9. Dispose of used fluid properly.

81

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. As engine coolant temperature decreases the con­tracting (cooled) coolant is drawn back up from the bottle, past the pres­sure cap, and into the radiator.

Some coolant level drop on new vehicles is normal as the system is
purging itself of trapped air. Check the coolant level and maintain as
recommended by adding coolant to the recovery bottle.

POLARIS recommends the use of POLARIS Premium 60/40 anti­freeze/coolant or a 50/50 mixture of high quality aluminum compatible
anti-freeze/coolant and distilled water. POLARIS Premium 60/40 is
already premixed and ready to use. Do not dilute with water. See page
126 for the part numbers of POLARIS products.

Always follow the manufacturer's mixing recommendations for the
freeze protection required in your area.

82

MAINTENANCE

Cooling System

Recovery Bottle Coolant

The recovery bottle is located
on the left side of the vehicle.

1. Remove the left side panel.

See page 86.

2. Maintain the coolant level
between the minimum and
maximum marks on the
bottle (when the fluid is
cool).

3. Add coolant as needed.

Recovery

Bottle

83

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.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap
while the engine is warm or hot. Always allow the engine to cool before
removing the pressure cap.

1. Open the front box cover.

2. Remove the access panel
screws. Squeeze the outer
edges of the panel inward to
remove the panel.

3. Remove the pressure cap.

4. Using a funnel, slowly add
coolant through the radiator
filler neck.

5. Reinstall the pressure cap.
Use of a non-standard pres­sure cap will not allow the
recovery system to function
properly. Contact your dealer
for the correct replacement part.

6. Reinstall the access panel and secure the front box cover.

Radiator

Cap

84

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. Do not overfill.

WARNING! An over-full master cylinder may cause brake drag or brake lock­up, which could result in serious injury or death. Maintain brake fluid at the
recommended level. Do not overfill.

The following checks are recommended to keep the brake system in
good operating condition. Check more often if brakes are used heavily
under normal operation.

1. Always keep brake fluid at an adequate
level. See page 30.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace brake pads when
they are worn to 3/64" (1 mm).

5. Check the security and surface condition

of the disc. Clean any grease using a rec­ommended brake cleaner or alcohol. Do
not use spray lubricants or other petroleum-based products. If you
discover any damage (cracks, excessive corrosion, warping) see
your dealer for service before operating.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 32.

3/64" (1 mm)

85

MAINTENANCE

Toe Alignment

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

straight-ahead position.

3. Tie a length of string

between two stands as
shown in the illustration.
Position the stands so
that the string is flush
with the side of the rear
tire. If available, you
may use a long straight­edge instead of string.

4. Measure the distance

from the string to the
rim at the front (1) and
rear (2) of the front rim.
The rear measurement
should be 1/16"-1/8" (2-3 mm) more than the front measurement on
each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6
mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your POLARIS dealer for

service.

String

Stand

2

1

FRONT

86

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. When reinstalling side panels, align the fasteners and press firmly to
secure them.

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.

3. Remove the footwell.

Step 1 Step 2 Step 3

Screws

Rivets

87

MAINTENANCE

Tires

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 124 for recom­mended tire type, size and pressure.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 1/8" (3 mm)
or less.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com­ponent operations. All service must be performed by your authorized
POLARIS dealer.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

WARNING! Do not service axle nuts that have a cotter pin installed. See your
POLARIS dealer.

5. Elevate the side of the vehicle by placing a suitable stand under the
footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

WARNING

1/8" (3 mm)

88

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. Always ensure that all nuts are torqued to
specification.

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos­ened for service.

Nut Type Nut Torque

Lug Nut
(Aluminum
Wheels)

30 ft. lbs. (41 Nm)

PLUS 1/4 TURN

2-Piece
Flange Nut
(Steel
Wheels)

27 ft. lbs. (37 Nm)

89

MAINTENANCE

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. Reinstall the air box cover and the seat.

Main Filter

Pre-Filter

90

MAINTENANCE

Breather Filter/Hose

The breather filter is on the hose that runs between the engine and air
box.

1. Remove the left side panel.
See page 86.

2. Remove the hose clamps

from the filter 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. Reinstall the filter and hose clamps.

Tip: The filter is effective with the arrow pointing in either direction.
NOTICE: Operation of your vehicle without a breather filter can cause engine

damage. Always reinstall the breather filter after removing it for
service.

Breather Filter

91

MAINTENANCE

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
the rear storage box.

1. Open the front box cover.

2. Remove the suspect fuse from
the fuse panel. If the fuse is
blown, install a new fuse with
the same amperage.

3. Close the front box cover.

Fuse Feature Supported

5A Speedometer

20A (Main Fuse) Ignition, Lighting

20A Accessories, 12V Power Receptacle

Fuse Panel

Fuses

5or61520 20

92

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. If fingers do touch a lamp, clean it with
denatured alcohol.

1. Remove the two screws on the lower front corners of the headlight
pod.

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the pod.

4. Lift the pod cover and disconnect the speedometer harnesses from

the speedometer.

CAUTION! Hot components can cause burns to skin. Allow lamps to cool
before servicing.

5. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring.

6. Turn the lamp counter-clockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp. Make

sure the tab on the lamp locates properly in the housing.

8. Reassemble the pod.

93

MAINTENANCE

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.

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. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight

pod. Adjust the beam to the desired position by turning the knob
either clockwise or counter-clockwise.

Low Beam Adjustment

The low beam can be adjusted slightly
upward or downward.

1. Loosen the phillips screw located at the
rear of the headlamp.

2. Tilt the headlamp upward or down-

ward.

3. Tighten the screw.

25 ft.

(7.6 m)

2" (5 cm)

Phillips

Screw

94

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. Lift the adjusting knob up to remove it from the locking tabs.

8. Carefully pull the assembly up

and out of the pod.

9. Reverse the steps to install the

new housing and reassemble
the pod. The distance from the
headlamp parting line to the
end of the adjustment knob
stop is 5 1/8" (13 cm).

10. Adjust the headlight aim by

turning the adjusting knob.

5 1/8"

(13 cm)

95

MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight
harness counter-clockwise 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 clock-

wise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

1. Remove the harness connector
from the back of the light assem­bly.

2. Turn the lamp counter-clockwise

to remove it.

3. Apply dielectric grease to the

socket and install the new lamp.

4. Reinstall the harness connector.

5. Test the light for proper operation.

Harness

Lamp

Connector

96

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 124 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.

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color. See page 97.

CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Using the special wrench provided in the tool pouch, rotate the
spark plug counter-clockwise to remove it.

3. Reverse the procedure for spark plug installation. Torque to specifi­cation.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)