Polaris ACE 570 User Manual

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Failure to heed the warnings and safety precautions

contained in this manual can result in severe injury or death.

Read this manual carefully.

SPORTSMAN ACE

SPORTSMAN ACE 570

™

Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals

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

or other reproductive harm.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

•RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles 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. Review the safety DVD that came with your vehicle. POLARIS also recommends that all drivers take the ROHVA safety e-course and a ROHVA hands-on safety training course. Visit www.rohva.org or call 866-267-2751.

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.

POLARIS®, SPORTSMAN® and SPORTSMAN ACE™ are trademarks of POLARIS Industries Inc.

Copyright 2014 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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

Printed in U.S.A. 2015 SPORTSMAN ACE/SPORTSMAN ACE 570 Owner’s Manual P/N 9924307

TABLE OF CONTENTS

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

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

Features and Controls. . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Emission Control Systems . . . . . . . . . . . . . . . 80

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 132

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 134

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 135

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 146

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

INTRODUCTION

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

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.

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. Your POLARIS vehicle is not a toy and can be hazardous to operate. This vehicle handles differently than cars, trucks or other off-road vehicles. 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 and review the safety DVD that came with your vehicle. A free extra copy of the DVD can be obtained by contacting your local POLARIS dealer. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.

• Never operate this vehicle without proper instruction. Take an authorized training course. Visit www.rohva.org or call 866-267-2751.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and have a valid driver’s license to operate this vehicle.

• Always use the cab nets (or doors) while riding in this vehicle. Always keep hands, feet and all other body parts inside the vehicle at all times.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

• Never use this vehicle with drugs or alcohol, as these conditions impair judgment and reduce operator reaction time.

• Complete the New Operator Driving Procedures outlined on pages 56-57. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures.

• Never permit a guest to operate this vehicle unless the guest has reviewed the owner’s manual and all safety labels and has completed a 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 controlled as

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

factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

INTRODUCTION

Key

Number

VIN

(Right Front Frame)

####

570

325

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.

Engine Serial

Number

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number (VIN): _________________________________________

Engine Serial Number: ___________________________________________________

Key Number____________________________________________________________

SAFETY

Safety Training

Safety training is a top priority for POLARIS. POLARIS strongly encourages you and any family members who will be riding this vehicle to take a training course.

ROHVA (Recreational Off-Highway V ehicle Association) provides both an online safety e-course and a hands-on safety course. Visit www.rohva.org or call 866-267-2751.

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

W e 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 recreational off-road vehicle safety in the United States, visit www.rohva.org, call 866-267-2751 or call POLARIS at 800-342-3764.

SAFETY

Safe Riding Gear

Always wear helmet, eye protection, gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all times. Protective gear reduces the chance of injury.

Long

Sleeves

Long

Pants

Over-the-Ankle

Boots

Gloves

Helmet

Eye

Protection

Helmet

W earing a helmet can prevent a severe head injury . Whenever riding this POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in 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

051039

0006.31

number will also be displayed on the label.

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding this POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Wear gloves for comfort and for protection from sun, cold weather and other elements.

Boots

Wear sturdy over-the-ankle boots for support and protection. Never ride a POLARIS vehicle with bare feet or sandals.

Clothing

Wear long sleeves and long pants to protect arms and legs.

Rider Comfort

Under certain operating conditions, heat generated by the engine and exhaust system can elevate temperatures in the rider cab area. The condition occurs most frequently when a vehicle is being operated in high ambient temperatures at low speeds and/or high load conditions for an extended period of time. The use of certain windshield, roof and/or cab systems may contribute to this condition by restricting airflow. Any discomfort due to heat buildup in this area can be minimized by wearing proper riding apparel and by varying speeds to increase airflow.

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions of the labels on the vehicle carefully. If any of the labels depicted in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

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

General Warning

SAFETY

Rollovers have caused

severe injuries and death,

even on flat, open areas.

Safety Labels and Locations

General Warning

WARNING Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid driver’s license.

• Do not let people drive after using alcohol or drugs.

• Do not allow operation on public roads (unless designated for off-highway vehicle access) - collisions with cars and trucks can occur.

• Do not exceed seating capacity: 1 occupant.

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belt.

• Wear an approved helmet and protective gear.

• ALWAYS use vehicle cab nets and/or doors.

• Driver must be able to sit with back against seat, feet flat on the floor, and hands on steering wheel. Stay completely inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding, skidding or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even from a stop.

• Plan for hi lls, rough terrain, ruts and other changes in traction and terrain.

• Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

Be Sure to Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk of injury:

• Keep a firm grip on the steering whee l and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA TRAINING (rohva.org).

7180534

SAFETY

Load/Passenger/Tire

Pressure Warning

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

WARNING

• Never carry passengers in cargo box.

• Passengers can be thrown off. This can cause serious injury or death.

WARNING

IMPROPER TIRE PRESSURE OR OVERLOADING CAN CAUSE LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Reduce speed and allow greater distance

for braking when carrying cargo.

• Overloading or carrying tall, off-center, or

unsecured loads will increase your risk of losing control. Loads should be centered and carried as low as possible in box.

• For stability on rough or hilly terrain,

reduce speed and cargo.

SPORTSMAN ACE

MAXIMUM CARGO BOX LOAD 240 lbs.

TIRE PRESSURE IN PSI (KPa) FRONT 7 (48)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

(108 kg)

REAR 7 (48)

575 lbs. (260 kg)

7180636

Maximum Payload Warning

WARNING

Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg).

7181835

SAFETY

Safety Labels and Locations

PVT System Warning

WARNING

Improper service or maintenance of this PVT system can result in vehicle damage, SEVERE INJURY or DEATH.

Always look for and remove debris inside and around clutch and vent system when replacing belt.

Read owner's manual or see authorized Polaris dealer.

7177469

Hitch Capacity Label

TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND 850 LBS. (386 KG) UP TO 15 DEGREES HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

PVT System Warning

7170509

SAFETY

WARNING

Safety Warnings

Failure to operate this vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual and in the safety DVD provided with your vehicle. See the OPERATION section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction increases the risk of an accident. The operator must understand how to operate the vehicle properly in different situations and on different types of terrain. Complete the New Operator Driving Procedures outlined on pages 56-57.

All operators must read and understand the owner's manual and all warning and instruction labels before operating the vehicle. Never allow a guest to operate this vehicle until the guest has completed the New Operator Driving Procedures outlined on pages 56-57.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 ye ars of age or anyone without a valid driver’s license.

The operator must be tall enough to sit with back against the seat, both feet flat on the floor and both hands on the steering wheel.

Using Alcohol or Drugs

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

Never consume alcohol or drugs before or while operating this vehicle.

SAFETY

Safety Warnings

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident.

Always perform the pre-ride inspection before each use of your vehicle to make sure it's in safe operating condition. See page 51.

Always follow the inspection and maintenance procedures and schedules described in this owner’s manual. See page 81.

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.

Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of rollover, loss of control, other accident or sudden stop. Seat belts may reduce the severity of injury in these circumstances.

The operator MUST wear the seat belt at all times.

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Always use the cab nets (or doors) while riding in this vehicle. Always keep hands and

feet inside the vehicle at all times.

SAFETY

Safety Warnings

Carrying a Passenger

This POLARIS vehicle is a single-rider vehicle. Carrying a passenger greatly reduces the operator's ability to control the vehicle, which may result in an accident or rollover. Carrying a passenger in the cargo box could result in a fall from the vehicle or contact with moving components. Never carry a passenger on this vehicle.

Operating With a Load on the Vehicle

The weight of both cargo and operator impacts vehicle operation and stability. For your safety and the safety of others, carefully consider how your vehicle is loaded and how to safely operate the vehicle. Follow the instructions in this manual for loading, tire pressure, gear selection and speed.

• Do not ex ceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the specifications section of this manual and on a label on the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, 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.

• The recommended tire pressures are listed in the specifications section of this manual and on a label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions: Do ALL of these steps:

Operator and/or cargo exceeds half the maximum weight capacity

Operating in rough terrain Operating over obstacles Climbing an incline Towing

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when operating.

Safety Warnings

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control or accident.

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

Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement. Operating this vehicle on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the vehicle and may increase the risk of loss of control and accident or rollover. Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and avoid sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets, roads or highways could result in a collision with another vehicle. Never operate this vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use). In some areas it's unlawful to operate this vehicle on public streets, roads and highways.

SAFETY

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Always operate at a speed that's appropriate for the terrain, the visibility and operating conditions and your skills and experience.

SAFETY

Safety Warnings

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow proper procedures for turning as described in this owner’s manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt steering maneuvers. Practice turning at slow speeds before attempting to turn at faster speeds.

Jumps and Stunts

Exhibition driving increases the risk of an accident or rollover. DO NOT do power slides, “donuts”, jumps or other driving stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of control or rollover. Use extreme caution when operating on hills. Always follow proper procedures for hill climbing as described in this owner's manual. See page 60.

Descending Hills Improperly

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for traveling down hills as described in this owner’s manual. See page

62.

Safety Warnings

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hillside is unavoidable, always follow proper procedures as described in this owner's manual. See page 61.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause a rollover. Maintain a steady speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle is fully stopped. Place the transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

Operating in Unfamiliar Terrain

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

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

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

SAFETY

Safety Warnings

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 65.

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

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of control, accident or rollover.

Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure as described in this owner's manual and on safety labels.

Skidding or Sliding

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover. Do not operate on excessively slippery surfaces. Always slow down and use additional caution when operating on slippery surfaces.

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this owner's manual. See page 59.

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or rollover.

Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as large rocks and fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles. See page 64.

SAFETY

Safety Warnings

Operating Through Water

Operating through deep or fast-flowing water can cause loss of traction, loss of control, rollover or accident. Never operate in fast-flowing water or in water that exceeds the floor level of the vehicle.

Always follow proper procedures for operating in water as described in this owner’s manual. See page 63.

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

Operating on Frozen Bodies of Water

Severe injury or death can result if the vehicle and/or the operator fall through the ice. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. Vehicle operators assume all risk associated with ice conditions on frozen bodies of water.

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any rollover or other accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) seat belts, rollover protection devices, brakes, throttle and steering systems.

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Always follow the instructi ons in this owner’s manual for carrying cargo. See page 66.

• Never exceed the stated load capacity for this vehicle. See page 12.

• Cargo should be properly distributed and securely attached. See page 66.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance for braking.

Poor Visibility

Operating this vehicle in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This vehicle 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.

Refueling

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme cauti on whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame or sparks.

• Always use an approved gasol ine container to store fuel and remove the container from the vehicle before filling to avoid fuel ignition due to electrical static discharge.

• Do not smoke or allow open flames or sparks in or near the area where refueling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

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

SAFETY

Safety Warnings

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area. Operate this vehicle only outdoors or in well-ventilated areas.

Hot Exhaust Systems

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

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by someone under the age of 16, without a drivers license, or without proper training. This could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used as directed. Modifications to your vehicle may negatively impact vehicle stability. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. This vehicle may become less stable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for the purpose of increasing speed or power. Any modifications or installation of non-POLARIS-approved accessories could create a substantial safety hazard and increase the risk of bodily injury.

The warranty on your POLARIS vehicle will be terminated if any non-POLARISapproved equipment and/or modifications have been added to the vehicle that increase speed or power.

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

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

FEATURES AND CONTROLS

Hip

Bars

Cargo

Box

Shifter

Cab Nets

Steering

Wheel

Throttle

Pedal

Brake Pedal

ROPS Frame

Front Box

Cover

Headlights

Taillights

Engine

Intake

Pre-Filter

Radiator

Single-Rider

Seat

Brush Guard

Fuel Cap

Component Locations

FEATURES AND CONTROLS

Rear Access Panel

Trailer Receiver Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. Trailer towing equipment is not supplied with this vehicle.

To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 66-68.

Service Access Panels

Access serviceable engine components through the engine access panel behind the seat. Remove the seat and release the access panel latches to remove the access panel.

Remove rear access panel to access the air box and spark plug. The rear access panel is located in the bed of the cargo box. Pull the rear edge of the access panel upward to remove it.

Receiver Hitch

Radiator Access/Bumper Removal

The front bumper can be removed to clean debris from the radiator.

1. Remove the four (4) torx screws and six (6) plastic rivets.

2. Lift the front bumper to remove it from the vehicle.

Screws

Rivets

FEATURES AND CONTROLS

Adjustment

Lever

Cover Fasteners

Access Panel

Steering Wheel

The steering wheel can be tilted upward or downward for rider preference.

Lift and hold the steering wheel adjustment lever while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

Always make sure the steering wheel position does not impede proper operation of the brake pedal, throttle pedal and all other controls.

Front Box Cover

Remove the front box cover and access panel to access the radiator cap, coolant overflow bottle and brake master cylinder reservoir.

1. Turn the box cover fasteners 1/4 turn.

2. Lift the rear edge of the box

cover.

3. Using the pliers provided in

the tool kit, remove the two (2) push darts from the access panel. Remove the panel.

FEATURES AND CONTROLS

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases the risk of serious injury or death in the event of an accident or rollover. Cab nets (or doors) must be used at all times. Make sure all latches on both sides of the vehicle are secure before operating the vehicle.

Always inspect cab nets and latches for tightness, wear and damage before each use of the vehicle. Use the strap adjusters to tighten any loose straps. Promptly replace worn or damaged cab nets and latches with new cab nets and latches. Please see your authorized POLARIS dealer.

Extreme Use Battery

An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories, please see your POLARIS dealer. Ask your dealer to provide any installation procedures that may differ for an extreme use battery.

Cab Net Latches

Electronic Power Steering (EPS)

Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 37 for EPS Warning Indicator information.

FEATURES AND CONTROLS

Fuel Cap

The fuel tank filler cap is located on the right side of the vehicle near the seat. When refueling, always use either leaded or unleaded gasoline with a minimum pump octane number of 87 R+M/2 octane. Do not use

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

Seat

Seat Adjustments

Always make sure the seat position allows for proper access and operation of the brake pedal, throttle pedal and all other controls.

The seat release lever is located at the left side of the seat. Push the release lever downward and slide the seat forward or rearward to the desired position. Release the lever. The seat will lock into the new position.

Seat Removal

1. Push the seat release lever downward and slide the seat forward until it slides off the frame.

2. Lift the seat away from the

vehicle.

3. Reverse the procedure to reinstall

the seat.

Fuel Cap

Seat Release

Lever

FEATURES AND CONTROLS

Retractor

Housing

Latch

Housing

Seat Belt

This POLARIS vehicle is equipped with three-point lap and diagonal seat belts. Always secure the seat belt before riding.

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch downward and across your chest toward the buckle at the inner edge of the seat. The belt should fit snugly across your hips and diagonally across your chest. Make sure the belt is not twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self-tighten.

4. Press the red release latch on the buckle to release the seat belt.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly into the buckle. A click indicates that it's securely latched.

2. Push the red release latch in the middle of the buckle to make sure it releases freely.

3. Pull each seat belt completely out and inspect the full length for any damage, including cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not operate properly , have the seat belt system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water. Do not use bleach, dye or household detergents.Use a garden hose to flush out the retractor and latch housing regularly.

FEATURES AND CONTROLS

Switches

Instrument Cluster

AWD Switch

Ignition Switch/Light Switch

12V Accessory

Outlet

FEATURES AND CONTROLS

OFF START

Switches

Ignition Switch/Light Switch

Use the ignition switch to start the engine and to turn the lights on or off. The key can be removed from the switch when it is in the OFF position.

OFF Turn the key to the OFF

LIGHTS ON The lights are on. Electrical

LIGHTS OFF The lights are off. Electrical

START Turn the key to the START

All Wheel Drive (AWD) Switch (if equipped)

The AWD Switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD).

Press the top of the rocker switch to engage All Wheel Drive. Press the bottom of the switch to operate in two wheel drive.

See page 35 for AWD operating instructions.

position to stop the engine. Electrical circuits are off.

circuits are on. Electrical equipment can be used.

position to engage the electric starter. See page 54 for starting procedures.

AWD

2WD

Auxiliary Outlet

The vehicle is equipped with a 12-volt accessory outlet on the dash. Use the outlet to power an auxiliary light or other optional accessories or lights. For service, the dash outlet connection is under the dash.

FEATURES AND CONTROLS

Gear Selector

To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear. Do not attempt to shift gears with engine speed above idle or while the vehicle is moving.

P: Park R: Reverse N: Neutral L: Low Gear

H: High Gear

Gear

Selector

NOTICE: Do not attempt to shift the transmission while the vehicle is moving or

damage to the transmission could result. Always shift when the vehicle is stationary and the engine is at idle.

Using Low Range

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

FEATURES AND CONTROLS

Throttle

Pedal

Brake Pedal

Depress the brake pedal to slow or stop the vehicle. Apply the brakes while starting the engine.

Throttle Pedal

Push the pedal down to increase engine speed. Spring pressure returns the pedal to the rest position when released. Always check that the throttle pedal returns normally before starting the engine. Make sure there's adequate throttle pedal freeplay. See page 109.

This vehicle 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 pedal, engine speed will be limited, and power to the rear wheels will be reduced.

FEATURES AND CONTROLS

ROPS Label

(on ROPS behind rear cab)

Rollover Protective Structure (ROPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover. When used with seat

belts and cab nets, the ROPS helps prevent occupants from being ejected from the vehicle. Always follow all safe operating practices outlined in this manual to avoid vehicle rollover.

WARNING! Vehicle rollover could cause severe injury or death. Always avoid operating in a manner that could result in vehicle rollover.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2WD (2X4), the vehicle is in two-wheel drive at all times. When the switch is on AWD (4x4), the vehicle is in all wheel drive and the 4X4 indicator in the instrument cluster will be on.

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.

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

Engaging A WD

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

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

NOTICE: Switching to AWD while the rear wheels are spinning or slipping may

cause severe drive shaft and gearcase damage. Always switch to AWD while the rear wheels have traction or are at rest.

AWD

2WD

FEATURES AND CONTROLS

Rider Information

Center

Speedometer

Indicator

Lamps

MODE Button

Instrument Cluster

High water pressure may damage components. Wash the vehicle by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens.

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h). See page 40.

Mode Button

Use the MODE button to toggle through mode options. See page 40 for operation of the modes.

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle Speed

Over Temperature

Neutral This lamp illuminates when the transmission is in High Beam (if

equipped) Helmet/Seat

Belt Check Engine This indicator appears if an EFI-related fault occurs.

EPS Warning (if equipped)

When standard mode is selected, speed displays in miles per hour.

When metric mode is selected, speed displays in kilometers per hour.

This lamp illuminates to indicate an overheated engine. If the indicator flashes, the overheating condition remains, and the system will automatically reduce engine power.

neutral and the ignition key is in the ON position. This lamp illuminates when the headlamp switch is

set to high beam. This lamp flashes for several seconds when the key is

turned to the ON position. The lamp is a reminder to wear helmet and seat belt before operating.

Do not operate the vehicle if this warning appears. Serious engine damage could result. See your dealer.

This indicator illuminates when the key is turned to the ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

The information center is set to display standard units of measurement and a 12-hour clock at the factory . To change to metric and/or a 24-hour clock, see page 41.

Trip 1

RPM

1. Gear Indicator - This indicator displays gear shifter position.

H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

-- = Gear Signal Error (or shifter between gears)

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your POLARIS dealer.

3. Information Display Area - This area displays odometer, trip meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an RPM too low to keep the battery charged. It may also occur when the engine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Drive at a higher RPM or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 41 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service interval has been reached. The vehicle should be brought to your POLARIS dealer for scheduled maintenance. See page 41 for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is engaged (switch is on 4X4).

8. Turf Mode Indicator (if equipped) - This indicator illuminates when the operator unlocks the differential.

FEATURES AND CONTROLS

MODE Button

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the information area options.

Display Units (Standard/Metric)

The display can be changed to show either standard or metric units of measurement for each of the following settings.

Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key

on. The gauge display the mode that was displayed prior to setting the units.

Standard Display Metric Display

Distance Miles Kilometers Fuel U.S. Gallons Liters, Imperial Gallons Temperature Fahrenheit Celsius Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

2. Press and hold the MODE button while turning the key to the ON position.

3. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button to save the setting and advance to the next display option.

5. Repeat the procedure to change remaining display settings.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or

discharged.

1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.

2. Press and hold the MODE button until the hour segment flashes. Release the button.

3. With the segment flashing, tap the MODE button to advance to the desired setting.

4. Press and hold the MODE button until the next segment flashes. Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Odometer Mode

The odometer records and displays the distance traveled by the vehicle.

Trip Meter Mode

The trip meter records the distance traveled by the vehicle if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Engine Temperature Mode

This mode displays current temperature of the coolant.

Tachometer Mode

The engine RPM is displayed digitally.

Tip: Small fluctuations in the RPM from day to day may be normal because of

changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Programmable Service Interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Instrument Cluster

Rider Information Center

Engine Error Codes

The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored. When the key is turned OFF, the code and message is lost, but will reappear if the fault reoccurs after restarting the engine.

If the CHECK ENGINE light illuminates, retrieve the error codes from the display.

1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code menu.

3. Record the three numbers displayed in the gear position, clock and odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See pages 44-45 for code definitions and failure descriptions. Please see your POLARIS dealer for all major repairs.

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.

Shorted Load

shorted together, or the item has shorted internally.

Short-to-Battery

the electronic control unit is shorted to a wire at battery voltage.

Component Condition SPN FMI

Accelerator Position 2

Throttle Position Sensor 1

Vehicle Speed Sensor

Accelerator Position 1

Manifold Absolute Pressure Sensor

: The wires leading to the item listed in the chart are

: The wire leading from the item listed in the chart to

Diagnostic Codes

Data Erratic, Intermittent Or Incorrect 29 2 Voltage Above Normal, Or Shorted T o High Source 29 3 Voltage Below Normal, Or Sh orted To Low Source 29 4 Data Valid But Above Normal Operational Range - Most

Severe Level Data Valid But Below Normal Operational Range - Most

Severe Level Data Erratic, Intermittent Or Incorrect 51 2

Voltage Above Normal, Or Shorted T o High Source 51 3 Voltage Below Normal, Or Sh orted To Low Source 51 4 Abnormal Rate Of Change 51 10 Out Of Calibration 51 13 Data Valid But Above Normal Operational Range - Most

Severe Level Data Valid But Below Normal Operational Range - Most

Severe Level Data Erratic, Intermittent Or Incorrect 84 2

Voltage Above Normal, Or Shorted T o High Source 84 3 Voltage Below Normal, Or Sh orted To Low Source 84 4 Abnormal Frequency Or Pulse Width Or Period 84 8 Abnormal Update Rate 84 9 Abnormal Rate Of Change 84 10 Bad Intelligent Device Or Component 84 12 Received Network Data In Error 84 19 Data Erratic, Intermittent Or Incorrect 91 2 Voltage Above Normal, Or Shorted T o High Source 91 3 Voltage Below Normal, Or Sh orted To Low Source 91 4 Data Erratic, Intermittent Or Incorrect 102 2 Voltage Above Normal, Or Shorted T o High Source 102 3 Voltage Below Normal, Or Sh orted To Low Source 102 4 Mechanical System Not Responding Or Out Of Adjustment 102 7 Abnormal Rate Of Change 102 10

51 0 51 1

84 0 84 1

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Intake Air Temperature Sensor

Engine T emperature Sensor

System Power Data Valid But Above Normal Operational Range - Most

Engine Speed Data Valid But Above Normal Operational Range - Most

Gear Sensor Signal Data Erratic, Intermittent Or Incorrect 523 2

ECU Memory Bad Intelligent Device Or Component 628 12

Calibration Out Of Calibration 630 13 Crankshaft Position

Sensor Injector 1 (Front)

(MAG) (SDI Port Injector)

Data Erratic, Intermittent Or Incorrect 105 2 Voltage Above Normal, Or Shorted To High Source 105 3 Voltage Below Normal, Or Shorted To Lo w So urce 105 4 Abnormal Rate Of Change 105 10 Data Valid But Above Normal Operating Range - Least

Severe Level Data Valid But Above Normal Operational Range - Most

Severe Level Data Erratic, Intermittent Or Incorrect 110 2

Voltage Above Normal, Or Shorted To High Source 110 3 Voltage Below Normal, Or Sho r ted To Low Source 110 4 Abnormal Rate Of Change 110 10 Data Valid But Above Normal Operating Range - Least

Severe Level Data Val id But Above Normal Operat ing Range - Moderately

Severe Level Data Valid But Below Normal Operating Range - Least

Severe Level Severe Level

Data Valid But Below Normal Operational Range - Most Severe Level

Voltage Above Normal, Or Shorted To High Source 168 3 Voltage Below Normal, Or Sho r ted To Low Source 168 4 Data Val id But Above Normal Operat ing Range - Moderately

Severe Level Data Valid Bu t Below Normal Operating Rang e - Moderately

Severe Level Severe Level

Data Valid But Below Normal Operational Range - Most Severe Level

Data Erratic, Intermittent Or Incorrect 190 2 Mechanical System Not Responding Or Out Of Adjustment 190 7 Received Network Data In Error 190 19 Condition Exists 190 31

Voltage Above Normal, Or Shorted To High Source 523 3 Voltage Below Normal, Or Sho r ted To Low Source 523 4 Abnormal Update Rate 523 9

Out Of Calibration 628 13

Data Erratic, Intermittent Or Incorrect 636 2 Abnormal Frequency Or Pulse Width Or Period 636 8 Voltage Above Normal, Or Shorted To High Source 651 3 Voltage Below Normal, Or Sho r ted To Low Source 651 4 Current Below Normal Or Open Circuit 651 5

105 15 110 0

110 15 110 16 110 17 168 0 168 1

168 16 168 18 190 0 190 1

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Fan Relay Driver Circuit

Ignition Coil Primary Driver 1 (Front) (MAG)

Fuel Pump Driver Circuit

Oxygen Sensor 1 Data Erratic, Intermittent Or Incorrect 3056 2

ECU Output Supply Voltage 1

ECU Output Supply Voltage 2

ECU Output Supply Voltage 3

ETC Accelerator Position Sensor Outputs 1 & 2 Correlation

Voltage Above Normal, Or Shorted To High Source 1071 3 Voltage Below Normal, Or Sho r ted To Low Source 1071 4 Current Below Normal Or Open Circuit 1071 5 Voltage Above Normal, Or Shorted To High Source 1268 3 Voltage Below Normal, Or Sho r ted To Low Source 1268 4 Current Below Normal Or Open Circuit 1268 5 Voltage Above Normal, Or Shorted To High Source 1347 3 Voltage Below Normal, Or Sho r ted To Low Source 1347 4 Current Below Normal Or Open Circuit 1347 5

Voltage Above Normal, Or Shorted To High Source 3056 3 Voltage Below Normal, Or Sho r ted To Low Source 3056 4 Bad Intelligent Device Or Component 3056 12 Data Valid But Above Normal Operational Range - Most

Severe Level Data Valid But Below Normal Operational Range - Most

Severe Level Voltage Above Normal, Or Shorted To High Source 3597 3

Voltage Below Normal, Or Sho r ted To Low Source 3597 4 Data Val id But Above Normal Operat ing Range - Moderately

Severe Level Data Valid But Below Normal Operating Ran ge - Moderately

Severe Level Data Valid But Above Normal Operational Range - Most

Severe Level Data Valid But Below Normal Operational Range - Most

Severe Level Voltage Above Normal, Or Shorted To High Source 3598 3

Voltage Below Normal, Or Sho r ted To Low Source 3598 4 Data Val id But Above Normal Operat ing Range - Moderately

Severe Level Data Valid But Below Normal Operating Ran ge - Moderately

Severe Level Data Valid But Above Normal Operational Range - Most

Severe Level Data Valid But Below Normal Operational Range - Most

Severe Level Voltage Above Normal, Or Shorted To High Source 3599 3

Voltage Below Normal, Or Sho r ted To Low Source 3599 4 Data Val id But Above Normal Operat ing Range - Moderately

Severe Level Data Valid But Below Normal Operating Ran ge - Moderately

Severe Level Data Erratic, Intermittent Or Incorrect 65613 2

3597 0 3597 1

3597 16 3597 18 3598 0 3598 1

3598 16 3598 18 3599 0 3599 1

3599 16 3599 18

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor 2 Data Valid But Above Normal Operational Range -

Active Descent Control System

Fuel Correction Front Data Valid But Above Normal Operating Range -

All Wheel Drive Control Circuit

Oxygen Sensor Heater 1 Data Erratic, Intermittent Or Incorrect 520209 2

Accelerator Position/Brake Position Interaction

Throttle Position Sensor (1 or 2 Indeterminable)

Throttle Body Control Power Stage

Throttle Body Control Return Spring Check Failed

Throttle Body Control Adaption Aborted

Throttle Body Control Limp Home Position Check Failed

Throttle Body Control Mechanical Stop Adaptation Failure

Throttle Body Control Repeated Adaptation Failed

Throttle Body Control Data Erratic, Intermittent Or Incorrect 520283 2

Most Severe Level Data Valid But Below Normal Operational Range -

Most Severe Level Data Erratic, Intermittent Or Incorrect 520198 2

Voltage Above Normal, Or Shorted To High Source 520198 3 Voltage Below Normal, Or Shorted To Low Source 520198 4 Abnormal Rate Of Change 520198 10 Out Of Calibration 520198 13 Voltage Above Normal, Or Shorted To High Source 520203 3 Voltage Below Normal, Or Shorted To Low Source 520203 4 Current Below Normal Or Open Circuit 520203 5

Least Severe Level Data Valid But Below Normal Operating Range -

Least Severe Level Voltage Above Normal, Or Shorted To High Source 520207 3

Voltage Below Normal, Or Shorted To Low Source 520207 4 Current Below Normal Or Open Circuit 520207 5

Voltage Above Normal, Or Shorted To High Source 520209 3 Voltage Below Normal, Or Shorted To Low Source 520209 4 Current Below Normal Or Open Circuit 520209 5 Condition Exists 520275 31

Data Erratic, Intermittent Or Incorrect 520276 2 Bad Intelligent Device Or Component 520276 12 Data Erratic, Intermittent Or Incorrect 520277 2 Voltage Above Normal, Or Shorted To High Source 520277 3 Voltage Below Normal, Or Shorted To Low Source 520277 4 Abnormal Frequency Or Pulse Width Or Period 520277 8 Condition Exists 520277 31 Condition Exists 520278 31

Condition Exists 520279 31 Condition Exists 520280 31

Condition Exists 520281 31

Condition Exists 520282 31

Voltage Above Normal, Or Shorted To High Source 520283 3 Voltage Below Normal, Or Shorted To Low Source 520283 4

520198 0 520198 1

520204 15 520204 17

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Throttle Body Control - Position Deviation Fault

ECU Monitoring Error Condition Exists 520286 31 ECU Monitoring Error (Level 3) Condition Exists 520287 31 ECU Monitoring of Injection Cut Off

(Level 1) ECU Monitoring of Injection Cut Off

(Level 2) Throttle Body Control - Requested

Throttle Angle Not Plausible ECU ADC Fault - No Load Condition Exists 520306 31

ECU ADC Fault - Voltage Condition Exists 520307 31 Accelerator Sensor Sync Fault - Sensor

Diff Exceeds Limit ECU Fault - ICO Condition Exists 520309 31

ECU Fault - Hardware Disruption Condition Exists 520311 31 Idle Fuel Correction Bank 1 Data Valid But Above Normal

Adaptive Fuel Correction Bank 1 Data Valid But Above Normal

Condition Exists 520284 31

Condition Exists 520288 31 Condition Exists 520289 31 Condition Exists 520305 31

Condition Exists 520308 31

Operating Range - Least Severe Data Valid But Below Normal

Operating Range - Least Severe Operating Range - Least Severe

Data Valid But Below Normal Operating Range - Least Severe

520342 15 520342 17 520344 15 520344 17

OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner’s manual.

Vehicle Break-in Period

The break-in period for your new POLARIS vehicle is the first 25 hours of operation, or the time it takes to use the first two tanks full of gasoline. No single action on your part is as important as a proper breakin period. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components. Perform the following procedures carefully.

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

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

Use of any oils other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS PS-4 Full Synthetic 5W-50 4-Cycle Oil for your 4-cycle engine.

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 28. Always exercise extreme caution whenever handling gasoline.

2. Check the oil level. See page 88 (325) or page 91 (570). Add the

recommended oil as needed to maintain the oil level in the safe operating range.

3. Complete the New Operator Driving Procedures outlined on pages

56-57.

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Pull only light loads.

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

on the daily pre-ride inspection checklist. See page 51.

8. During the break-in period, change both the oil and the filter at 25

hours or one month.

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

hours of operation and every 100 hours thereafter.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or overly forceful braking when the brake system is new could damage brake pads and rotors.

PVT Break-in (Clutches/Belt)

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

If a belt fails, always clean any debris from the PVT intake and outlet duct and from the clutch and engine compartments when replacing the belt.

OPERATION

Pre-Ride Inspection

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases the risk of an accident. Always inspect the vehicle before each use to make sure it's in safe operating condition.

Item Remarks Page

Brake system/pedal travel

Brake fluid Ensure proper level 112 Front suspension Inspect, lubricate if necessary 85 Rear suspension Inspect, lubricate if necessary 85 Steering Ensure free operation 114 Tires Inspect condition and pressure 12

Wheels/fasteners Inspect, ensure fastener tightness 1 15 Frame nuts, bolts, fas-

teners Fuel and oil Ensure proper levels 39

Coolant level Ensure proper level 101-102 Coolant hoses Inspect for leaks Throttle Ensure proper operation 109 Indicator lights/switches Ensure proper operation 31 Air filter, pre-filter Inspect, clean 106 Intake pre-filters Inspect, clean 107 Headlamps Check operation, apply POLARIS

Brake light/tail lamps Check operation, apply POLARIS

Seat Latch Push down on the seat back to Seat Belt Check length of belt for damage, Cab Nets Check for wear or damage, ensure

Ensure proper operation 33

111

115

Inspect, ensure tightness -

88, 91

117 dielectric grease when lamp is replaced

119 dielectric grease when lamp is replaced

ensure the latch is secure

check latches for proper operation

proper installation

OPERATION

Safe Operation Practices

1. Visit the Recreational Off-Highway Vehicle Association web site and take the free on-line training course. Complete the recommended safety training before operating this vehicle. Visit www.rohva.org or call 866-267-2751.

2. Do not allow anyone under 16 years of age or without a valid

driver’s license to operate this vehicle.

3. Never carry a passenger on this vehicle.

4. Engine exhaust fumes are poisonous. Never start the engine or let it

run in an enclosed area.

5. Never operate with accessories not approved by POLARIS for use

on this vehicle.

6. Operate this vehicle off-road only . Never operate this vehicle on any

public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

7. 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.

8. Always operate at a speed that's appropriate for the terrain, the

visibility and operating conditions and your skills and experience. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Keep both hands on the steering wheel during operation.

9. Never consume alcohol or drugs before or while operating this

vehicle.

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

Always maintain proper tire pressure.

11. Never operate a damaged vehicle. After any rollover or accident,

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

OPERATION

Safe Operation Practices

12. Never operate the vehicle on a frozen body of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

13. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

14. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area. Respect the environment in which you ride your vehicle. 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 . T read 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.

OPERATION

OFF START

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a wellventilated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the

engine.

5. Turn the ignition key to the START

position. Engage the starter for a maximum of five seconds. Release the key when the engine starts. Turn the key to either LIGHTS ON or LIGHTS OFF.

6. If the engine does not start within

five seconds, return the ignition switch to the OFF position and wait five seconds. Repeat steps 5 and 6 until the engine starts.

7. Vary the engine RPM slightly with

the throttle to aid in warm up until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Cold Weather Operation

If the vehicle 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.

OPERATION

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is released completely and engine speed slows to near idle, the vehicle has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and stopping (using the brakes) until you're familiar with the controls.

Parking the Vehicle

1. Stop the vehicle on a level surface. When parking inside a garage or other structure, be sure that the structure is well ventilated and that the vehicle is not close to any source of flame or sparks, including any appliance with pilot lights.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

OPERATION

New Operator Driving Procedures

1. Read and understand the owner's manual and all warning and instruction labels before operating this vehicle.

2. Visit the Recreational Off-Highway Vehicle Association web site

and take the free on-line training course. Visit www.rohva.org or call 866-267-2751. Hands-on training is also available through ROHVA.

3. Perform the pre-ride inspection. See page 51.

4. Do not tow or carry cargo during this period.

5. Select an open area that allows room to familiarize yourself with

vehicle operation and handling.

6. The driver must wear helmet, eye protection, gloves, long-sleeve

shirt, long pants, over-the-ankle boots and seat belt at all times.

7. Sit in the driver's seat and fasten the seat belt.

8. Make sure all cab nets are properly secured.

9. Place the transmission in PARK.

10. Start the engine.

OPERATION

New Operator Driving Procedures

11. Apply the brakes and shift into low gear.

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

13. Keeping both hands on the steering wheel, slowly release the brakes and depress the throttle with your right foot to begin driving.

14. Drive slowly at first. On level surfaces, practice starting, stopping, turning, maneuvering, using the throttle and brakes and driving in reverse. Learn how the vehicle handles when making both left and right turns at a slow speed.

WARNING! Operating in TURF mode (if equipped) when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

• Operate at speeds appropriate for your skills, the conditions and

the terrain.

• DO NOT do power slides, “donuts”, jumps or other driving

stunts.

OPERATION

Turning the Vehicle

Your vehicle is equipped with a solid rear axle, which drives both rear wheels equally at all times. This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly.

To turn the vehicle, rotate the steering wheel in the direction of the turn.

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

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

Driving on Slippery Surfaces

OPERATION

Sideways

skid

Turn in

direction of

skid

When driving on slippery surfaces such as wet trails, loose gravel, or ice, be alert for the possibility of skidding and sliding. Follow these precautions when encountering slippery conditions:

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down before entering slippery areas.

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

4. Engage all-wheel drive before wheels begin to lose traction.

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

while the wheels are spinning. Always allow the wheels to stop spinning before engaging AWD.

5. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the brakes during a skid.

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending any hill. Never drive on hills with excessively slippery or loose surfaces.

2. Never operate in TURF mode (if equipped) while operating on a hill

or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill.

3. Avoid excessively steep hills. If ascending a steeper grade is

unavoidable, engage all-wheel drive before ascending.

4. Drive straight uphill.

5. Proceed at a steady rate of speed and throttle opening. Never open

the throttle suddenly.

6. Avoid unnecessary changes in speed or direction.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp

drop, or another vehicle or person could be on the other side of the hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the

transmission in reverse and slowly allow the vehicle to roll straight downhill while applying light brake pressure to control speed.

OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill.

3. Drive slowly and use extreme caution.

4. If the vehicle begins to overturn, or if it feels as if it may overturn, immediately turn downhill.

5. Avoid obstacles and changes in terrain that may lower or raise one side of the vehicle or cause the vehicle to slide.

6. If the vehicle begins to slide downhill, immediately turn downhill to stop the slide, or stop the vehicle and maneuver slowly and carefully until the vehicle can be driven straight downhill.

OPERATION

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid excessively steep hills.

2. Never operate in TURF mode (if equipped) while operating on a hill or other irregular terrain. Always move the AWD switch to AWD before ascending or descending a hill.

3. Slow down. Never travel down a hill at high speed.

4. Always check the terrain carefully before descending a hill. Never drive on hills with excessively slippery or loose surfaces.

5. Always descend a hill with the transmission in forward gear. Never descend a hill with the transmission in neutral.

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

7. Apply the brakes lightly to aid in slowing.

OPERATION

Driving Through Water

Your vehicle can operate through water with a maximum recommended depth equal to floor level. Follow these precautions when operating through water:

1. Determine water depth and current before entering water.

2. Choose a crossing where the water level is lowest and where both banks have gradual inclines. Never operate in water that exceeds the maximum recommended depth.

WARNING! The large tires on your vehicle may cause the vehicle to float in deep or fast-flowing water, which could result in loss of traction, loss of control, rollover or accident.

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

NOTICE: Major engine damage can result if the vehicle is not thoroughly

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 81. Give special attention to engine oil, transmission oil, demand drive fluid, rear gearcase oil (if equipped) and all grease fittings.

If your vehicle becomes immersed or is operated in water that exceeds the floor level, take it to your POLARIS dealer for service before starting the engine. If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 119, and take the vehicle to your dealer at the first opportunity.

Floor Level

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

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

4. Avoid operating over large obstacles such as large rocks and fallen trees. If unavoidable, use extreme caution and operate slowly.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle.

2. Apply the throttle lightly. Never apply throttle suddenly.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

Parking on an Incline

A rolling vehicle can result in serious injury . Avoid parking on an incline. If parking on an incline is unavoidable, follow these precautions:

1. Place the transmission in PARK.

2. Turn the engine off.

3. Block the rear wheels on the downhill side, or park the vehicle in a sidehill position instead.

OPERATION

WARNING

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability. Always follow these precautions when hauling cargo:

Never exceed the stated load capacity for this vehicle. 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, 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.

Always load the cargo box with the load as far forward and as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions. Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available. SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle. OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. 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 vehicle rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle should never exceed 10 MPH (16 km/h) while towing a load on a level grass 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.

Never exceed 43 MPH (70 km/h) if total payload exceeds 335 lbs. (152 kg). Carrying a passenger in the cargo box could

result in a fall from the vehicle or contact with moving components. Never allow a passenger to ride in the cargo box.

OPERATION

Hauling Cargo

Your POLARIS vehicle has been designed to carry or tow specific capacities. Reduce speed and allow a greater distance for braking when carrying cargo.

Loads should be centered and carried as low as possible in the box. For stability on rough or hilly terrain, reduce both speed and cargo. Exercise caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on warning labels and in this manual. Never exceed the maximum capacities specified for your vehicle. See page 132.

Belt Life

To extend belt life, use low gear when hauling or towing heavy cargo.

OPERATION

WARNING

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake instability.

Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the towing bracket.

2. When towing a disabled vehicle, place the disabled vehicle’s

transmission in neutral. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing.

3. Towing a trailer increases braking distance. Do not operate the

vehicle faster than 10 MPH (16 km/h) when towing.

4. Do not tow more than the recommended weight for the vehicle.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a

trailer to any other location, which could result in loss of control of the vehicle.

6. The total load (operator, accessories, cargo and weight on hitch)

must not exceed the maximum weight capacity of the vehicle.

Total Towed

Load Weight

(Level Ground)

1500 lbs.

(681 kg)

Total Towed

Load Weight

(15° grade)

850 lbs. (386 kg)

Total Hitch

Vertical

Weight

150 lbs.

(68.1 kg)

Maximum

Towing

Speed

10 MPH

(16 km/h)

WINCH GUIDE

WARNING

These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.

Winch Safety Precautions

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the winch.

5. Always keep body, hair, clothing and jewelry clear of the winch cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 78.

7. Always keep the area around the vehicle, winch, winch cable, and load clear of people (especially children) and distractions while operating the winch.

8. Always turn the vehicle ignition power OFF when it and the winch are not being used.

9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

WINCH GUIDE

Winch Safety Precautions

10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.

12. If winching at an angle is unavoidable, follow these precautions:

A. Look at the winch drum occasionally. Never let the winch cable “stack”

or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 76 to feed

and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s rated capacity.

15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

16. Never touch, push, pull or straddle the winch cable while winching a load.

17. Never let the winch cable run through your hands, even if wearing heavy gloves.

WINCH GUIDE

Winch Safety Precautions

18. Never release the clutch on the winch when the winch cable is under load.

19. Never use the winch for lifting or transporting people.

20. Never use the winch to hoist or suspend a vertical load.

21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs.

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage to winch components.

24. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.

25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.

WINCH GUIDE

WARNING

Winch Operation

Read the Winch Safety Precautions in the preceding pages before using your winch.

Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 feet (1 meter)

of winch cable if the winch is being used (or has been used) for lifting an accessory plow assembly. Promptly replace any worn or

damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your

vehicle’s park brake and/ or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.

Hook Strap

WINCH GUIDE

NO YES

Winch Operation

4. Always use the hook strap when handling the hook.

WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY.

A. Attach the hook itself onto the

load or use a tow strap or chain to secure the load to the winch cable.

Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 78.

B. Never hook the winch cable back onto itself. This will damage the

winch cable and may result in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the

winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a

tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly® (treadlightly.org).

E. Before operating the winch , be sure

that the safety latch on the winch cable hook is fully seated when the load is attached.

F. Never operate your winch with a

damaged hook or latch. Always replace damaged parts before using the winch.

YES

WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.

8. Read and adhere to the following information for winch damping to ensure safe winch use.

A. In order to absorb energy that could be relea sed by a winch cable

failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.

B. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

C. On a long pull, it may be necessary to stop winching so that the

damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.

D. Avoid being directly in line with the winch cable whenever possible.

Also, never permit others to stand near or in line with the winch cable during winch operation.

9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or worn.

WINCH GUIDE

Winch Operation

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winchequipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 78. For your safety, always follow these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch

cable.

B. Align the winch cable as close as possible to the winching vehicle’s

centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the

direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.

13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods.

WINCH GUIDE

Winch Operation

14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.

15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task.

A. Release the clutch on the winch. B. Feed out the winch cable th at is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 100 lbs. (45

kg) of tension using the hook strap.

E. Slowly winch the cable in while your assistant moves the end of the

winch cable back and forth horizontally to evenly distribute the winch cable on the drum.

F. Doing this reduces the chances of the winch cable “wedging” itself

between lower layers of winch cable.

WINCH GUIDE

Winch Cable Care

For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

WARNING! Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn or kinked winch cable.

A. A kinked winch cable made of

wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.

B. A kinked winch cable made of

wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.

C. A winch cable made of

synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.

D. Also replace the winch cable if there are fused or melted fibers. Such

an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.

WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic,

or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It generates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).

This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an

object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are

designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.

5. Never use the winch to tie down a vehicle to a trailer or other

transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and winch cable are NOT designed for shock loading.

WINCH GUIDE

Winch Maintenance and Service Safety

WARNING! Improper or lack of winch maintenance and service could lead to

SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.

1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.

2. Permit your winch motor to cool down prior to servicing your winch.

3. Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.

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.

Y our 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

Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.

The emissions label is located on the inside of the lower left frame tube (below driver’s foot area).

Emissions Label

(inside of 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.

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 146.

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

Vehicles subjected to heavy or severe use patterns must be inspected and serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• 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 POLARIS dealer.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Symbol Description

Ź 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.

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.

Item Maintenance Interval

Steering Front suspension Rear suspension Tires Brake fluid level Brake pedal travel Brake system Wheels/fasteners Frame fasteners Engine oil level Intake pre-filters Winch (if

equipped) Coolant - Daily - Check level Power steering unit

(if equipped) Headlamp/tail

lamp

Air filter,

main element

Brake pad wear 10 H Monthly 100 (160) Inspect periodically

Engine breather 25 H Monthly 150 (250) Inspect; replace if necessary

Battery 25 H Monthly 250 (400) Check terminals; clean; test Fuel System 25 H Monthly - Inspect; cycle key to

(whichever comes first)

Hours Calendar Miles (Km)

Pre-Ride

- - See pages 69-79

- Daily - Inspect daily; clean often

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

Inspect and make adjustments as need ed. See Pre-Ride Checklist on page 51.

dielectric grease if replacing

pressurize fuel pump; check lines and fittings for leaks and abrasion

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Ź Engine oil change 25 H 1 M - Break-in oil and filter change Ź Demand drive fluid 25 H 1 M - Break-in oil level check Ź Transmission oil

(main gearcase)

Throttle cable 50 H 6 M 300 (500) Inspect; adjust; lubricate;

E E Throttle body air

intake ducts/flange

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

Ź Oil lines, fasteners

(if equipped) Shift Linkage 50 H 6 M 500 (800) Inspect, lubricate, adjust

D Steering 50 H 6 M 500 (800) Lubricate

Ź Front Suspension 50 H 6 M 500 (800) Lubricate Ź Rear Suspension 50 H 6 M 500 (800) Lubricate

Cooling system 50 H 6 M 500 (800) Inspect coolant strength

Ź Engine oil change 100 H 6 M - Change the oil and filter

DEFuel system 100 H 12 M 600 (1000) Cycle key to pressurize fuel

Spark plug 100 H 12 M 600 (1000) Inspect; replace as needed

Ź Demand drive fluid 100 H 12 M - Change fluid Ź Transmission oil

(main gearcase)

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

Ź Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks Ź Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles (Km)

25 H 1 M - Break-in oil level check

replace if necessary

50 H 6 M 300 (500) Inspect duct for proper seal-

50 H 6 M 500 (800) Inspect for leaks and loose

100 H 12 M - Change fluid

100 H 12 M 1000 (1600) Inspect

ing/air leaks

cables, etc.

fittings

seasonally; pressure test system yearly

pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years

surfaces

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

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

D Clutches (drive

and driven) Drive belt 100 H 12 M 1000 (1600) Inspect; replace as needed

D Front wheel

bearings

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

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

Ź Coolant - 60 M - Replace coolant

Valve clearance 500 H - 5000 (8000) Inspect; adjust as needed

E D Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

Ź Perform these procedures more often for vehicles subjected to severe use.

E Emission-Related Service D Have an authorized POLARIS dealer perform these services.

(whichever comes first)

Hours Calendar Miles (Km)

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

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

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

parts

when parts are replaced

Remarks

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 81, or more often under severe use, such as wet or dusty conditions. Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.

Transmission Oil (Main Gearcase)

Demand Drive Fluid (Front Gearcase)

Prop Shaft U-Joint Grease Locate fittings and grease. Rear Control Arm Pivot

Bushings, Front A-Arm Bushings

Stabilizer Bar Bushings, Tie Rod Bushings, Ball Joint Boots

AGL Gearcase Lubricant & Transmission Fluid

Demand Drive Fluid See page 94.

All Season Grease or grease conforming to NLGI No. 2

See page 88 (325) or page 91 (570).

See page 112. See page 95.

Locate fittings and grease.

Prop Shaft

Grease Fitting

MAINTENANCE

Rear Control

Arm Pivot

Bushings

Stabilizer Bar

Bushings

Front A-Arm

Bushing

Tie Rod Bushing

Ball Joint

Boot

Lubrication Recommendations

MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W50 4-cycle oil for this engine.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated engine oil will cause accelerated wear and may result in engine seizure, accident, and injury. Always perform the maintenance procedures as outlined in the Periodic Maintenance Chart.

Oil may need to be changed more frequently if POLARIS PS-4 engine oil is not used. Follow the manufacturer's recommendations for ambient temperature operation. See page 134 for the part numbers of POLARIS products.

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

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

MAINTENANCE

Oil Dipstick (Check/Fill)

Upper Oil Fill

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87.

NOTICE: Allowing dirt or debris to enter the engine can result in serious engine

Oil Check (325)

The oil dipstick is located on the lower engine, behind the seat. Access the dipstick through the right rear wheel well. Remove the dipstick to check the oil level and to add oil. An additional oil fill hole is located at the top of the engine. Add oil through either the dipstick hole or the upper fill hole. Access the upper fill hole cap through the cargo box access panel.

1. Position the vehicle on a level

2. Place the transmission in P ARK.

3. Always clean away all dirt and

4. Reinstall and tighten the

5. Remove the dipstick and check

6. Add the recommended fluid as

7. Reinstall and tighten the dipstick.

damage. Always clean away all dirt and debris from the dipstick area before removing the dipstick.

surface.

debris from the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

Full

dipstick.

the oil level.

needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

Add

MAINTENANCE

Spring

Filter

Sealing Washer

Drain

Plug

O-Ring

Filter Cover

Engine Oil

Oil and Filter Change (325)

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil.

The engine drain plug is located on the bottom of the crankcase.

1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes.

2. Start the engine. Allow it to idle for two to three minutes. Stop the engine.

3. Clean the area around the drain plug.

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

4. Place a drain pan beneath engine crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Install a new sealing washer on the drain plug.

Tip: The sealing surfaces on drain

plug and crankcase should be clean and free of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 11-13 ft. lbs. (14.5-17.5 Nm).

MAINTENANCE

Engine Oil

Oil and Filter Change (325)

8. Using a clean, dry cloth, clean the oil filter cover on the crankcase.

9. Place shop towels beneath the filter cover to catch oil drips. Remove the cover screws and remove the cover to access the oil filter.

10. Remove the oil filter and spring, retaining the spring for reinstallation.

11. Using a clean, dry cloth, clean the surface of the crankcase.

12. Lubricate the o-ring for the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition. Install the oring to the filter cover.

13. Reinstall the oil filter spring, then install the new filter.

14. Reinstall the oil filter cover and o-ring. Torque the screws to 88 in. lbs. (10 Nm).

15. Fill the sump with 1.75 quarts (1.65 l) of the recommended oil.

16. Reinstall the upper fill cap (if removed) and tighten the dipstick.

17. Make sure the transmission is in PARK. Apply the brakes.

18. Start the engine. Allow it to idle for one to two minutes.

19. Stop the engine. Inspect for leaks.

20. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

21. Dispose of used filter and oil properly.

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always use the recommended engine oil. See page 87.

Oil Check (570)

The oil dipstick and fill tube is located on the engine, behind the passenger seat. Access the dipstick through the right rear wheel well.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick. Wipe it dry with a clean cloth.

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

6. Add the recommended fluid as needed. Maintain the oil level in the safe range between the FULL and ADD marks. Do not overfill.

7. Reinstall and tighten the dipstick.

Full

Dipstick

Add

MAINTENANCE

Drain Plug Access

Engine Oil

Oil and Filter Change (570)

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Always change the oil filter whenever changing oil.

The engine drain plug is located on the bottom of the crankcase.

1. Position the vehicle on a level surface. Place the transmission in PARK. Apply the brakes.

2. Start the engine. Allow it to idle for

two to three minutes. Stop the engine.

3. Clean the area around the drain plug.

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

4. Place a drain pan beneath engine

crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the

drain plug.

Tip: The sealing surfaces on drain plug and crankcase should be clean and free

of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 12 ft. lbs. (16 Nm).

MAINTENANCE

Engine Oil

Oil and Filter Change (570)

8. Using a cap-style oil filter wrench, turn the filter counter-clockwise to remove it.

9. Using a clean dry cloth, clean the filter sealing surface on the crankcase. Make sure the old filter o-ring is completely removed.

10. 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.

11. Install the new filter and turn by hand until the filter gasket contacts the sealing surface, then turn and additional 1/2 turn.

12. Always clean away all dirt and debris from the dipstick area before removing the dipstick. Remove the dipstick and fill the sump with two quarts (1.9 l) of recommended oil.

13. Reinstall and tighten the dipstick.

14. Make sure the transmission is in PARK. Apply the brakes.

15. Start the engine. Allow it to idle for one to two minutes.

16. Stop the engine. Inspect for leaks.

17. Re-check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

18. Dispose of used filter and oil properly.

Oil Filter

MAINTENANCE

Fill Level

Fill Plug

Drain Plug

Gearcases

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 81. Refer to the Gearcase Specifications Chart on page 96 for recommended lubricants, capacities and torque specifications.

Fluid Check

The fill plug is located on the bottom right side of the demand drive unit. Access the fill plug through the right front wheel well. Maintain the fluid level even with the bottom thread of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

Check the fluid level.

3. Add the recommended

fluid to the bottom thread of the fill plug hole.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

The drain plug is located on the bottom of the gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.

5. Reinstall the drain plug. Torque to specification.

6. Add the recommended fluid to the bottom thread of the fill plug

hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

MAINTENANCE

Fill Plug

Drain Plug

(between rear tires)

Gearcases

Transmission (Main Gearcase)

Fluid Check

The fill plug is located on the rear of the gearcase. Maintain the fluid level at the bottom of the fill plug hole.

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the fluid level.

3. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

4. Reinstall the fill plug. Torque to specification.

Fluid Change

The drain plug is located on the bottom of the gearcase between the rear tires. Access the drain plug through the drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug. Allow the fluid to drain completely.

3. Clean the drain plug. Reinstall the drain plug with a new o-ring. Torque to specification.

4. Add the recommended fluid to the bottom of the fill plug hole. Do not overfill.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks. Discard used fluid properly.

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See page 134 for the part numbers of POLARIS products.

Gearcase Lubricant Capacity Fill Plug

Transmission

(Main Gearcase)

Demand Drive Unit

(Front Gearcase)

AGL Gearcase

Lubricant &

Transmission

Fluid

Demand Drive

Fluid

44 oz. (1300 ml) 10-14 ft. lbs.

9 oz.

(265 ml)

(14-19 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

Torque

Drain Plug/

Level Check

Plug Torque

10-14 ft. lbs.

(14-19 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

Spark Plug

Spark Plug Gap/Torque

Electrode Gap New Plug Torque Used Plug Torque

0.8 +/- 0.1 mm 9 ft. lbs. (12 Nm) 9 ft. lbs. (12 Nm)

NOTICE: Using non-recommended spark plugs can result in serious engine

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

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

damage. Always use POLARIS-recommended spark plugs. Refer to the specifications section beginning on page 132.

MAINTENANCE

Spark Plug

Spark Plug Removal and Replacement

1. Remove the cargo box access panel.

2. Remove the spark plug cap.

3. Using the spark plug wrench provided in the tool kit, remove the plug by rotating it counter-clockwise.

4. Reverse the procedure for spark plug installation. Torque to specification. See page 96.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil, use of non-recommended injection oil or incorrect throttle body adjustments.

MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical failures, a fuse may need replacement. Locate and correct any short circuits that may have caused the blown fuse, then replace the fuse.

Main Fuse Featur e Supported

20A Lights: Headlights, Taillights 20A Drive: AWD 20A Accessory: Winch Switch, 12V Power Receptacle 10A Fuel Pump 20A Electronic Engine Control, Starting 30A Engine Control 30A EPS (Optional) 10A Constant Vehicle Power 15A Fan Circuit Braker - Auto Reset

The fuse box is located under the seat. Spare fuses are provided in the fuse box.

Fuse Box

Polaris ACE 570 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual