Polaris ATV Sportsman 500 Tractor INTL User Manual

Download

Sportsman® 500

Tractor

2013

Owner's Manual

for Maintenance and Safety

It contains important safety information.

Operation is prohibited for those under 16 years of age.

Read this manual carefully.

This is an adult vehicle only.

Before you operate this vehicle, read the owner’s manual.

Lesen Sie die Bedienungsanleitung bevor Sie dieses Fahrzeug fahren.

Antes de conducir este vehículo, lea el Manual del propietario.

Lire le Manuel du propriétaire avant d’utiliser ce véhicule.

Prima di usare il veícolo, leggete il Manuale di istruzioni.

Lue aina käyttöohjekirja ennen tämän ajoneuvon käyttöä.

Antes de utilizar este veículo, leia o Manual do proprietário.

Innan du kör detta fordon, läs Handboken.

For your nearest Polaris dealer, visit www.polarisindustries.com

Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 U.S.A.

Part No. 9923938 Revision 01 Printed in U.S.A.

*9923938 *

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER® utility vehicles

• Victory Motorcycles®

• Low emission vehicles (LEVs) Always follow the instructions and recommendations in this manual.

The 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. Please see your dealer for all of your ser- vice needs during (and after) the warranty period.

POLARIS, THE WAY OUT and SPORTSMAN are registered trademarks of POLARIS Industries Inc.

Copyright 2012 POLARIS Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2013 Sportsman 500 Tractor Owner’s Manual P/N 9923938

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 20

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

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Emission Control Systems . . . . . . . . . . . . . . . 68

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

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

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 127

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

INTRODUCTION

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

INTRODUCTION

WARNING

Failure to follow the warnings in this manual can result in serious injury or death. A POLARIS Tractor is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS Tractor.

• Never operate this vehicle without proper instruction. Take a training course.

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

• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Tractor/ trailer combination on public roads is prohibited. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

CE Mark

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

SAFETY

Safety Training

Never operate this vehicle without proper instruction. Take a training course.

For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polarisindustries.com.

Read and understand your owner's manual, which includes valuable information about all aspects of your vehicle, including safe operating procedures.

Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.

Equipment Modifications

The warranty on your POLARIS Tractor may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power. The addition of certain accessories, including (but not limited to) mowers, blades, tires, sprayers and large racks may change vehicle handling. Use only POLARIS-approved accessories. Know their function and effect on the vehicle.

SAFETY

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Eye Protection

Gloves

Long Pants

Boots

Helmet

Long

Sleeves

Helmet

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 a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

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

Clothing

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

SAFETY

WARNING

Rider Safety

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the Tractor.

Never operate a Tractor without proper instruction. Take a training course. Beginners should receive training from a certified instructor. Contact an authorized POLARIS Tractor dealer or visit the POLARIS web site at www.polarisindustries.com.

Never permit others to operate the Tractor unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• Never fill a fuel container while it's on the vehicle. Static electricity between the rack and container could cause a spark.

• 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

Rider Safety

Engine exhaust contains poisonous carbon monoxide and can cause loss of consciousness resulting in severe injury or death. Never run an engine in an enclosed area.

Never carry a passenger on this vehicle.

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never consume alcohol or drugs before or while operating a Tractor.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions and your experience.

SAFETY

Rider Safety

Always inspect your Tractor before each use to verify that it's in safe operating condition. Follow the inspection and maintenance procedures outlined in this manual. See page 43.

Keep both hands on the handlebars. Keep both feet on the footrests.

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for turning. See page 47.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

SAFETY

Rider Safety

If a Tractor has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

Never attempt jumps or other stunts.

Always follow the procedures outlined in this manual for driving on hills. See page 48. Never operate on hills too steep for the Tractor or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.

Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 51.

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 50.

Never attempt to turn the Tractor around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

Use the front hitch for vehicle recovery or towing only. Always remove the front hitch before operating in forward gear. See page

28.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 52.

Always follow the procedures outlined in this manual for operating over obstacles. See page 57.

Always follow the procedures outlined in this manual for driving in reverse. See page 58.

Rider Safety

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 56.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page

54.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

SAFETY

Never modify a Tractor through improper installation or use of accessories.

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

SAFETY

Rider Safety

Never operate the Tractor on a frozen body of water.

Operating on paved surfaces may affect the handling and control of the Tractor and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

Always remove the ignition key when the vehicle is not in use to prevent unauthorized use or accidental starting.

Always unlock the steering before starting the engine. See page 27.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about Tractor safety,

contact an authorized POLARIS Tractor dealer or visit

the POLARIS web site at www.polarisindustries.com.

SAFETY

Hill Operation

and Hitch Alert

Age 16 Alert

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If a 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.

The following pages repeat the information found on each label.

General Alert (Multi-Lingual)

Before you operate this vehicle, read the owner’s manual.

7173025

General

Alert

Hill Operation/Hitch Alert

• Never operate this vehicle on HILLS steeper than 25 degrees 25°.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and

brakes gradually.

7175814

SAFETY

Reverse Override

Alert

“No Passenger”

Warning

Rack

Warning

Rack

Warning

Tire Pressure/

Load Alert

Clutch

Cover Alert

Safety Labels and Locations

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5) MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg) INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES. Read Owner's Manual for more detailed loading information.

7174877

Override Warning

WARNING Improper use of override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

4X4 (AWD) Caution

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

7175486

7175485

SAFETY

Safety Labels and Locations

“No Passenger” Warning

WARNING NEVER ride as a passenger. Passengers can cause a loss of control, resulting in

SEVERE INJURY or DEATH.

7175378

Clutch Cover Alert

NO STEP

7173030

Rack Warning

WARNING

• DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch.

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

7172572

FEATURES AND CONTROLS

Mode/Reverse

Override Switch

Main Key

Switch

4X4 Switch

Winch Switch

Momentary High-Beam

Switch

Work Light

Switch

Master Light

Switch

Switches

Master Light Switch

The master light switch must be in the ON position to allow operation of the headlights, parking lights and taillights.

Momentary High Beam Switch

Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released.

Winch Switch

See page 62 for winch information.

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 33. To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

The reverse override switch also acts as a MODE switch when held down for approximately one half second. See the instrument cluster information beginning on page 33.

Tip: The override switch will not function as a MODE switch if the transmission

is in reverse.

Activating the override switch while the throttle is open can cause loss of control. Do not activate the override switch while the throttle is open.

FEATURES AND CONTROLS

Override

Switch

Engine

Stop

Switch

Light

Switch

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

Switches

Main Key Switch

End all electrical power to the vehicle.

The LIGHTS ON position turns the headlights on. The master light switch must be on and the

engine stop switch must be in the RUN position.

Start the engine. The headlights are not on in this position.

After starting the engine, release the key switch to the PARKING LIGHTS ON position. The parking lights and taillights are on in

this position.

Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF (STOP)

Light Switch (High/Low Beam)

Use the light switch to change the headlights from high beam to low beam. The master light switch must be on to operate the headlights.

High Beam

Low Beam

RUN

FEATURES AND CONTROLS

Turn

Indicators

Work Light

Switch

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

4X4 Switch

Switches

Work Light Switch

The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road).

Turn Signal Switch

Push the toggle switch either left

or right to activate the corresponding turn signal light. The indicator on the pod will also flash. Return the toggle to the center position and push it inward to end the signal.

Hazard Warning Switch

Push the hazard warning switch to cause all turn signal lights to

flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Horn Switch

Press the horn switch to sound the horn.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page

30. The vehicle automatically

engages 4X4 when operating in reverse if the 4X4 switch is set to either 4X4 position.

FEATURES AND CONTROLS

Throttle Release Switch

Mirrors

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving the Tractor.

Throttle Lever

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate a Tractor with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Press the throttle lever to increase engine speed and vehicle movement.

Release the lever to reduce engine speed and vehicle movement.

Throttle Release Switch

The throttle release switch causes the engine to stop if the throttle cable sticks in an open position when the operator releases the throttle lever.

The throttle release switch stops the engine in the event of a throttle system malfunction. Do not modify this safety feature or replace it with other throttle mechanisms.

FEATURES AND CONTROLS

Brakes

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control. Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes. If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

Parking Brake

1. Place the transmission in PARK.

2. Squeeze the brake lever toward the han-

dlebar. Push the parking brake lock forward to engage the lock. Release the brake lever.

3. To release the parking brake lock,

squeeze and release the brake lever.

Foot Brake

Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

FEATURES AND CONTROLS

Seat

Seat Load Adjustment

Adjust the seat spring for the comfort of a lighter or heavier operator. Reach under the rear rack to access the adjuster. Tighten the spring for heavier riders. Loosen the spring for lighter riders.

Load Adjuster

Measure Preload

(shown with seat removed)

Use the following table to determine the best preload measurement for rider weight. Measure preload between the adjuster plate and the lower spring retainer.

Rider Weight Preload Measurement

Up to 39 kg 0 mm

39-94 kg 0-32 mm

Over 94 kg 32-64 mm

Driver's seat, type Seat One:

e11*78/764*2006/96*2056*00

FEATURES AND CONTROLS

Height Adjustment Slots

Backrest Knobs

Seat

Seat Removal

Lift the latch bar at the rear of the seat to release the latch. Tilt the seat slightly rearward to disengage the seat tabs from the rear seat base slots. Remove the seat.

Make sure the seat is securely installed before operating.

Seat Height Adjustment

To raise or lower the seat, remove the seat and reposition the seat tabs in one of the rear seat base slots. Make sure the seat is securely installed before operating.

Backrest Adjustment

Loosen the backrest knobs on each side of the backrest mount and slide the backrest forward or rearward to the desired position. Tighten the knobs securely.

FEATURES AND CONTROLS

Steering Lock

Lock the steering to prevent unauthorized use or theft of the vehicle.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

1. Turn the handlebars to the full right or

full left position.

2. Insert the steering lock key and turn it

clockwise. Remove the key.

3. Place the steering lock keys in a safe

place. The lock must be replaced if the keys are lost.

4. Reverse the procedure to unlock the

steering.

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane of 87. Do not use E-

85 fuel.

FEATURES AND CONTROLS

Hitches

See page 124 for hitch weight capacities.

Front Hitch

Use the front hitch for vehicle recovery or towing only. Do not use the front hitch for any other purpose. Always remove the front hitch before operating in forward gear.

Rear Hitch

Hitch specifications may differ from vehicle capacity specifications. Do not exceed the hitch and towing capacities specified for this vehicle. See page 124.

Use the rear hitch for towing a trailer. See pages 59-61 for procedures.

Rear Hitch Specifications

Material 1021 M Steel Fasteners 1008K Steel (Main Pin and Receiver Pin) Weld Length and Positions 3 mm fillet, both sides, all around Maximum Vertical Load 75 kg (on coupling point) Maximum Towable Mass 750 kg Approval # e11*89/173*2006/26*2073*xx

FEATURES AND CONTROLS

Step 2Step 1 Step 3

Hitches

Hitch Installation/Removal

1. Release the wire lock from the 12.7 mm pin and remove the pin.

2. Install the hitch to the receiver.

3. Install the 12.7 mm pin through the bore of both the receiver and the

hitch. Secure the wire lock. Make sure the hitch assembly is secure at that the wire lock is properly engaged over the pin.

4. To remove the hitch, release the wire lock, remove the hitch, rein-

stall the pin to the receiver and secure the wire lock.

FEATURES AND CONTROLS

Gear

Selector

Fuel Tank

Cap

Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

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

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

NOTICE: Shifting gears with the engine speed above idle or while the vehicle is

Belt Life

To extend belt life, use LOW forward gear when pulling a heavy load at less than 11 km/h for extended periods and when operating uphill at a slow speed.

All Wheel Drive (4X4) System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4

switch to ADC 4X4 before ascending or descending a hill.

See page 32.

moving can cause transmission damage.

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

4X4

When the switch is on 4X4, the vehicle is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.

When in 4X4, 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 4X4.

2X4

When the switch is on 2X4, the vehicle is in two-wheel drive at all times.

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving. 4X4 will not engage until engine speed is below 3100 RPM. 4X4 remains engaged until the switch is turned off. There is no limit to the length of time the vehicle may remain in 4X4.

If the switch is turned off while the demand drive unit is engaged, it will not disengage until the rear wheels regain traction. Engage 4X4 before getting into situations where maximum traction is needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may

cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.

Engaging Active Descent Control

The ADC system will automatically engage when all four of the following conditions occur:

• The 4X4 switch must be in the ADC 4X4 position

• Vehicle speed must be 24 km/h or less

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the following conditions occur:

• The 4X4 switch is moved out of the ADC 4X4 position

• Vehicle speed exceeds 24 km/h

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

The instrument cluster senses vehicle speed from the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles or kilometers, as well as hours of operation. It also includes a reverse speed limiter function that limits the vehicle's speed to approximately 11-14 km/h. Refer to page 20 for additional information.

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

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All segments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the vehicle to your POLARIS dealer for proper diagnosis.

1. Gear Indicator - This

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

2. 4X4 Indicator - This

indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Odometer/Tachometer/Tripmeter/ Hour Meter

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

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

7. Check Engine Warning Indicator - This indicator serves two pur-

poses. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the vehicle if this warning appears. Serious engine damage could result.

8. Mode Indicator

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 20. The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles or kilometers traveled by the Tractor.

Trip Meter Mode

The trip meter records the miles or kilometers traveled by the Tractor on each trip if it's reset before each trip. To reset the trip meter, select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode. To exit the diagnostic mode, turn the key switch off and on. Any movement of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

1. Turn the key switch off and wait 10 seconds.

2. Lock the parking brake.

3. Place the transmission in neutral.

4. Hold the mode/reverse override button and turn the key switch on.

Release the switch as soon as the display is activated.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the 4X4 coil (only on models with switchable 4X4). This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 38.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

or OFF appears in the Rider Information Center, depending on your preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

one hour. Press and hold the mode button to advance the hours quickly. If you scroll past the intended number, press and hold the button until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

Downloading Codes

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

See page 41 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in

PARK. Stop the engine. Turn the key switch to the ON position.

2. Turn the key switch off and

on three times in less than five seconds. The word “WAIt” will appear on the screen.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

3. The Check Engine icon will blink once, pause, then blink twice

(blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.

4. Count the number of times the Check Engine icon flashes.

Example: For the two blink codes 42 and 36, the Check Engine icon will flash 4 times, pause, then flash 2 times (code 42), then pause longer, blink 3 times, pause, and blink 6 times (code 36).

5. A code 61 will signal the end of the sequence. If no blink codes are

found, only codes 12 and 61 will appear during the sequence. The word “WAIt” will remain on the screen through this entire process.

Code Definitions

Open Load:

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

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.

There is a break in the wires that lead to the item listed in

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink Code

12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 47 IAC Stepper Motor: Open Load 47 IAC Stepper Motor: Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery 52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground 52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery 55 MIL Circuit: Open Load/Short-to-Ground 55 MIL Circuit: Shorted Load/Short-to-Battery 56 Fuel Pump: Open Load/Short-to-Ground 56 Fuel Pump: Shorted Load/Short-to-Battery 58 Fan Circuit: Open Load/Short-to-Ground 58 Fan Circuit: Shorted Load/Short-to-Battery 59 ADC: Open Load/Short-to-Ground 59 ADC: Shorted Load/Short-to-Battery 63 Starter Enable: Open Load/Short-to-Ground 63 Starter Enable: Shorted Load/Short-to-Battery 72 Gear Sensor Signal 73 4X4: Open Load/Short-to-Ground 73 4X4: Shorted Load/Short-to-Battery 61 END SEQUENCE

Failure Description

OPERATION

Break-In Period

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

Do not operate at full throttle or high speeds for extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 27.

2. Check the engine oil level. See page 74. Add oil if necessary.

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

vehicle operation and handling.

4. Drive slowly. Vary the throttle positions. Do not operate at sustained

idle.

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

on the daily pre-ride inspection checklist. See page 43.

6. Pull only light loads.

7. Change both the oil and the filter at 25 hours or one month, which-

ever comes first.

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

hours of operation and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.

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

OPERATION

Pre-Ride Checklist

Item Remarks Page

Hand brake/lever travel Ensure proper operation 91 Foot brake Ensure proper operation 91 Brake fluid Ensure proper level 91 Front suspension Inspect, lubricate if necessary 73 Rear suspension Inspect, lubricate if necessary 73 Steering/steering lock Unlock the steering; ensure free oper-

Steering Ensure free operation Tires Inspect condition and pressure 96 Wheels/fasteners Inspect, ensure fastener tightness 96

Frame nuts, bolts, fasteners Inspect, ensure tightness Fuel and oil Ensure proper levels 27

Coolant level (if applicable) Ensure proper level 86

Coolant hoses (if applicable) Inspect for leaks Throttle Ensure proper operation 23

Indicator lights/switches Ensure operation 20 Engine stop switch Ensure proper operation 21 Mirrors Adjust for best side/rear vision 23 Air filter, pre-filter Inspect, clean 98 Air box sediment tube Drain deposits whenever visible Headlamp Check operation, apply POLARIS

Brake light/taillight Check operation, apply POLARIS

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 84 Front Hitch Remove the front hitch (if installed) 28 Winch Inspect cable and switch 63-64

ation

dielectric grease when lamp is replaced

protective clothing

101

102

OPERATION

Starting the Engine

NOTICE: Operating the vehicle immediately after starting could cause engine

1. Position the vehicle on a level

2. Place the transmission in PARK

3. Sit on the vehicle.

4. Apply the brakes.

5. Move the engine stop switch to RUN.

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

7. Turn the ignition key past the PARKING

8. If the engine does not start, release the

9. Repeat steps 7 and 8 until the engine

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

surface.

(or neutral).

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

starter and wait five seconds.

starts.

OPERATION

Cold Weather Operation

Internal engine condensation increases as outside temperatures decrease. If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate condensation in the bottom of the oil tank, which can lead to engine damage. Any condensation must be drained.

Always operate the engine long enough to reach operating temperature, which reduces condensation. See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in cold weather.

PVT Operation

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 11 km/h Low

Towing heavy loads Low

Operating in rough or rugged terrain Low

Operating at speeds greater than 11 km/h High

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 43.

3. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

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

5. Apply the brakes.

6. Shift the transmission into gear.

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

8. Release the brakes.

9. Slowly squeeze the throttle lever toward the handlebar to begin

driving.

10. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

Turning the Vehicle

1. Before turning, activate

a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. Steer in the direction of

the turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.

3. Never turn quickly when

carrying cargo.

4. Practice making turns at

slow speeds before attempting to turn at faster speeds.

OPERATION

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

OPERATION

Driving Uphill

25° Maximum

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 32.

2. Avoid steep hills (25° maximum).

3. Avoid hills with slippery or loose surfaces.

4. Keep both feet on the footrests.

5. Shift body weight uphill.

6. Drive straight uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

OPERATION

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

3. Dismount on the uphill side, or on the left side if the vehicle is

pointed straight uphill.

4. Use the K-turn to turn around. See page 52.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 25°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Avoid hills with slippery or loose surfaces.

3. Avoid crossing the sides of steep hills.

4. Shift your weight uphill.

5. Keep your feet on the footrests.

6. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the Tractor around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 32.

2. Avoid steep hills (25° maximum).

3. Avoid hills with slippery or loose surfaces.

4. Never drive downhill at high speed. Slow down.

5. Drive straight downhill. Avoid driving downhill at an angle, which

can cause the vehicle to pitch sharply to one side.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

OPERATION

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

2.4 m

1. Stop the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 32.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. Dismount on the uphill side, or on the left side if the vehicle is

pointed straight uphill.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake.

8. Slowly release the brake lever and allow the vehicle to roll around

to your right until it's pointing across the hill or slightly downward.

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill.

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake.

14. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level ground.

Always follow the procedures outlined in this manual for climbing hills. Avoid climbing hills steeper than 25°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

OPERATION

Driving Through Water

Maximum

Depth

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If

it's unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

5. Wet brakes may have reduced stopping ability. Dry the brake pads

by driving slowly and applying the brakes lightly several times until braking action is normal.

OPERATION

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 106. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

If the vehicle stops while fully submerged, major engine damage can result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

OPERATION

Driving on Slippery Surfaces

Sideways

skid

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

Turn in

direction of

skid

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down before driving onto slippery surfaces.

2. Engage 4X4 before wheels begin to lose traction.

3. Be alert. Watch the trail.

4. Avoid quick, sharp turns.

5. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward.

6. Never apply the brakes during a skid.

NOTICE: Severe damage to drive train may occur if 4X4 is engaged while the

wheels are spinning. Engage 4X4 when the wheels have traction.

OPERATION

Driving Over Obstacles

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

2. Be alert. Watch the terrain. Use extra caution.

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Parking on an Incline

Avoid parking on an incline. If it's unavoidable, follow

these precautions:

1. Stop the engine.

2. Place the transmission

in PARK.

3. Always block the rear

wheels on the downhill side.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

backing.

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

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

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

OPERATION

Hauling Cargo

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

• Read and understand the load distribution warnings listed on the vehicle

warning labels.

• 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 racks and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed

load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load

high on the rack raises the center of gravity of the vehicle and creates a less stable operating condition. Reduce load weight when cargo is high. Secure off-centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn.

Split the load between the front rack and rear rack, with 1/3 in the front and 2/ 3 in the back. Do not exceed load capacities. See specifications beginning on page 124.

• 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.

• USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY. Operating a Tractor/trailer

combination on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when

towing loads in rough terrain, while cornering, or while ascending or descending hills.

OPERATION

Hauling Cargo

Always read and understand the load distribution warning labels on the vehicle. Never exceed the weight capacities specified for this vehicle.

2/3

1/3

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Tractor/trailer combination on public roads is prohibited. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road. Do not tow any trailer on a grade steeper than 15°.

• Use the front hitch for vehicle recovery or towing only. Always remove the front hitch before operating in forward gear.

• The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

• The total load (operator, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.

Capacities Rear Hitch Front Hitch

Maximum Towed Load (Level Ground) 557 kg 386 kg

Maximum Vertical Hitch Weight 55 kg 39 kg

Hauling Cargo

Towing Loads

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS Tractor. Always install POLARIS-approved (or equivalent) accessories designed for Tractor use.

OPERATION

Maximum

10 cm

WINCH GUIDE

WARNING

DANGER

Danger Zone

The responsibility for safe operation of the winch ultimately rests with you, the operator. Read and understand all safety precautions and operating instructions before operating the winch. Careless operation can result in serious injury. DO NOT use the winch to lift or move people.

Winch Safety Precautions

1. Be alert. Do not operate the winch under the influence of drugs,

alcohol or medication.

2. Practice using the winch so you are prepared to use it in an emer-

gency situation.

Never connect DC powered winches to AC current. Motor damage or fatal shock may occur.

Stand clear of the cable and load during winching. Keep helpers and spectators at a safe distance. If a cable pulls loose or breaks under the load, it can lash back with dangerous force.

3. Beware of the danger zone.

The danger zone is the area of the rotating wire cable drum, the fairlead (if fitted), the cable, the hook and the motor. Before placing hands in or near the danger zone, first relieve tension on load, then disconnect the control switch.

4. If you are within four feet (1.2 m) of the winch, do not hold the

cable and the remote (if equipped) at the same time.

WINCH GUIDE

Winch Cable Care

1. The life of a cable is directly related to the care it receives. The wire

cable on a new winch (and any replacement cables) must be respooled under a minimum of a 100-lb. (45.4-kg) load before use. Failure to do this will result in cable damage.

2. Inspect all cable before use. Mashed, pinched, frayed or kinked

areas severely reduce the load-carrying capability. Replace damaged cable promptly.

3. Prevent kinks before they occur.

A. This is a start of a kink. Straighten

the cable before using it.

B. The cable was pulled and the loop

has tightened to a kink. The cable is now permanently damaged and should not be used.

C. The result of kinking is that each

strand pulls a different amount of load, causing the strands under the greatest tension to break. This reduces the load capacity of the entire cable.

4. Before re-spooling, remove all load from the cable. Hold the han-

dlebar switch lead in one hand and the cable in the other. Move away from the vehicle as far as the switch will allow. Activate the switch, walk in several feet of cable, then release the switch. Repeat this process until the re-spooling is complete.

CAUTION! To avoid injury, always release the switch before your hand comes within four feet (1.2 m) of the fairlead (the physical opening through which the cable passes).

5. Be sure the cable is distributed evenly and tightly on the drum. A

loosely wound drum may allow the cable to work its way down into the layers of cable on the drum and become wedged.

6. Do not grease or oil the cable. Doing so causes dirt contamination

that will reduce the life of the cable.

WINCH GUIDE

DANGER

WARNING

DANGER

Winch Preparation and Inspection

Wear heavy leather gloves whenever handling cable. Do not allow the cable to slip through your hands, even with gloves on. When handling the hook, always use a handsaver. Never place fingers into the hook. Placing fingers in the hook could result in injury.

Inspect the switch and wiring for cracks, pinched spots, frayed wire or loose connections. A damaged, shortened lead could cause the winch to operate as soon as it is plugged in.

Never touch the cable or hook while they are in tension or under load. Even at rest, the winch may have the cable in tension. Never guide a cable under tension onto the drum with your hand.

1. Winch with at least five wraps of cable around

the winch drum. With fewer wraps, the cable could pull loose from the drum under load.

WINCH GUIDE

WARNING

Winch Rigging

Take your time when rigging and use extra caution. Improper rigging can result in injury in addition to damage to the vehicle and equipment. Never handle the cable or rigging while another person is at the control switch.

1. Use a nylon sling to

attach the cable to an anchor point.

CAUTION! Do not attach the hook back onto the cable. Doing so can cause the cable to break.

Always use a handsaver. Do not hold the hook with your hand. This is important not only when reeling cable in but also when removing cable from the winch under power.

2. Run the winch intermittently to take

up cable slack. When using a pulley block, be sure the cable is running properly in all pulleys before applying a load.

CAUTION! Never engage or disengage the clutch if the winch is under load, the cable is in tension or the drum is rotating.

WINCH GUIDE

Winch Operation

NOTICE: This winch is designed for intermittent use. Prolonged use may result

1. Use common sense.

2. Take your time.

3. Think through the situation.

4. Pay attention to what is going on when you are winching.

5. DO NOT overheat the winch motor. During extended winching,

6. Extended winching will discharge your battery. If the low battery

7. DO NOT overload or stall the winch. If the load is greater than the

8. Avoid continuous side pulls.

9. Never tow the vehicle by the winch cable.

10. Never use the winch cable as a tie-down.

11. Use an anchor point that is stronger than what you are pulling.

12. DO NOT hook the cable back onto itself. This will damage the

in damage due to overheating.

stop and feel the winch motor. The motor should be cool enough to touch. If not, allow the motor to cool before continuing.

warning light comes on, stop winching. Make sure the transmission is in neutral or park, then rev the motor for a few minutes until the warning light goes out. Recharge the battery as soon as possible.

winch is capable of pulling, use a snatch block.

cable.

WINCH GUIDE

Winch Operation

13. Use as much cable as possible when pulling. Additional wraps of

cable on the spool will significantly reduce the pulling power of your winch. If the winch is still not capable of pulling the load, use a snatch block.

14. Never pull with less than five wraps of cable on the spool.

15. Inspect the condition of the cable prior to pulling. If the cable is

frayed or damaged, replace it as soon as possible.

16. DO NOT submerge the winch in water.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrester

Your POLARIS vehicle has a spark arrester that was designed for onroad and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

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.

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian ICES-002 and EMC requirements of European directives 97/24/EC and 2004/108/EC.

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average riding conditions. Vehicles subjected to severe use must be inspected and serviced more frequently.

The programmable service interval mode on the instrument cluster will help determine when maintenance service is due. See page 33.

Record maintenance and service in the Maintenance Log beginning on page 134.

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.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold

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

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Symbol Description

 Perform these operations more often for vehicles subjected to severe use.

D Have an authorized POLARIS dealer perform these services.

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 lever - -

Foot brake - -

Brake system - -

Passenger seat lock-out

Wheels/fasteners - -

Frame fasteners - -

 Engine oil level - -

Winch - - See pages 63-64.

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

 Air box sediment

tube

Coolant - Daily - Check level daily, change

 ADC fluid - Daily - Check level daily, add as

Headlight/taillight/ work light

(whichever comes first)

Hours Calendar Kilometers

Pre-Ride

as needed

- Daily - Drain deposits when visible

coolant every 2 years

needed

- Daily - Check operation; apply dielectric grease if replacing lamps

Remarks

Inspect and make

adjustments as need ed.

See Pre-Ride Checklist on

page 43.

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

 Air filter,

main element

DBrake pad wear 10 Monthly 160 Inspect periodically

Battery 20 Monthly 320 Check terminals; clean; test

 Engine oil change

(break-in)

 Demand drive fluid

(extreme use)

 Demand drive fluid 25 1 M 400 Break-in oil level check

 Rear gearcase oil

(if equipped)

 Transmission oil 25 1 M 400 Break-in oil level check

 Engine breather

filter (if equipped)

 General

lubrication

Shift linkage 50 6 M 800 Inspect, lubricate, adjust

D Steering 50 6 M 800 Lubricate

 Front suspension 50 6 M 800 Lubricate

 Rear suspension 50 6 M 800 Lubricate

D Throttle cable/

throttle release switch

Throttle body intake duct

Drive belt 50 6 M 800 Inspect; adjust; replace as

Cooling system 50 6 M 1600 Inspect coolant strength

 Engine oil change 100 6 M 1600 Perform a break-in oil change

 Oil filter change 100 6 M 1600 Replace with oil change

 Oil tank vent hose

(if equipped)

(whichever comes first)

Hours Calendar Kilometers

- Weekly - Inspect; replace as needed

25 1 M 400 Perform a break-in oil change

25 1 M 400 Change fluid every 25 hours

25 1 M 400 Break-in oil level check

25 Monthly 400 Inspect; clean if needed

50 3 M 800 Lubricate all fittings, pivots,

50 6 M 800 Inspect; adjust; lubricate;

50 6 M 800 Inspect duct for proper seal-

100 6 M 1600 Inspect routing, condition

at one month

if ADC is subjected to extreme use. See page 82.

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

 Demand drive fluid

(normal use)

 Rear gearcase oil 100 12 M 1600 Change fluid

 Transmission oil 100 12 M 1600 Change fluid

D Valve clearance 100 12 M 1600 Inspect; adjust

D Fuel system 100 12 M 1600 Check for leaks at tank cap,

 Radiator 100 12 M 1600 Inspect; clean external

 Cooling hoses 100 12 M 1600 Inspect for leaks

 Engine mounts 100 12 M 1600 Inspect

Exhaust muffler/ pipe

D Spark plug 100 12 M 1600 Inspect; replace as needed

 Wiring 100 12 M 1600 Inspect for wear, routing,

D Clutches (drive

and driven)

D Front wheel

bearings

D Brake fluid 200 24 M 3200 Change every two years

D ADC fluid 200 24 M 3200 Change every two years

DFuel filter 200 24 M 3200 Replace every 2 years, more

Spark arrester 300 36 M 4800 Clean out

D Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

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

(whichever comes first)

Hours Calendar Kilometers

100 12 M 1600 Change fluid

lines, filter, pump; replace lines every 2 years

surfaces

100 12 M 1600 Inspect

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

100 12 M 1600 Inspect; clean; replace worn

100 12 M 1600 Inspect; replace as needed

parts

often under severe use

when parts are replaced

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 69. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Capacity at

Method

Fluid Change

Engine Oil PS-4 PLUS Perfor-

Brake Fluid DOT 4 Only --- See page 88.

Transmission Oil AGL PLUS

Demand Drive Fluid (Front Gearcase)

ADC Fluid Demand Drive PLUS

Front Prop Shaft Yoke

mance Synthetic 2W-50

Transmission Fluid

Demand Drive PLUS Fluid

Fluid

POLARIS Premium UJoint Lube

2 qt. (1.9 l) See page 74.

32 oz. (948 ml) See page 80.

9.3 oz. (275 ml) See page 82.

--- See page 84.

--- Grease fittings (3 pumps maximum) every 800 km, before long periods of storage, or after pressure washing or submerging.

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 PLUS Performance

Synthetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to be changed more frequently if POLARIS oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation.

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

Oil Specifications

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

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

Lubricant Capacity Drain Plug Torque

1.9 liters 19-23 N-m

Engine Oil

Safe

Add Oil

Safe Range

{

Oil Level

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Remove the dipstick.

Wipe it dry with a clean cloth.

6. Reinstall the dipstick

completely.

MAINTENANCE

Dipstick

7. Remove the dipstick and check the oil level. Add oil as needed.

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

8. Reinstall the dipstick.

MAINTENANCE

Engine Oil

Oil and Filter Change

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Clean the area

around the drain plug.

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

8. Drain the oil.

Drain

Plug

New Sealing Washer

Screen

Fitting

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 74.

MAINTENANCE

Engine Oil

Oil and Filter Change

11. Disconnect the lower oil delivery hose and remove the screen fitting from the oil tank. Clean the fitting. Seal the fitting threads with LOCTITE PST 505 or PTFE seal tape.

12. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank. Do not over-tighten. Maxi-

mum torque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter. Using an oil filter wrench, turn the filter counter-clockwise to remove it.

15. Clean the filter sealing area on the crankcase.

Alignment Mark

16. Lubricate the filter o-ring. Check to make sure the o-ring is in good condition.

17. Install the new oil filter. After the filter contacts the crankcase surface, turn it 1/2 turn by hand.

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

TIP: The sealing surfaces on the drain plug and crankcase should be clean and

free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to 19 N-m.

MAINTENANCE

Safe

Add Oil

Safe Range

{

Engine Oil

Oil and Filter Change

20. Remove the dipstick.

21. Add 1.9 liters of recommended oil.

TIP: If the sump is not drained, add

about 1.6 liters initially.

22. Reinstall the dipstick.

23. Place the transmission in PARK.

24. Prime the oil pump using the procedure on page 79.

25. Stop the engine. Check for oil leaks.

26. Check the oil level. Add oil as needed. Maintain the oil level in the safe range. Do not overfill.

27. Reinstall the dipstick.

28. Discard used oil and filter properly.

MAINTENANCE

Clamp

Pressure

Relief Slit

Ta nk

5 cm

Engine Oil

Oil and Filter Change

Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp the vent line 5 cm from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

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

hear a rush of air. If you do not hear a rush of air, repeat the priming procedure.

MAINTENANCE

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the recommended oil.

See page 126 for the part numbers of POLARIS products.

Transmission Oil Recommendations

Lubricant Oil Change

Premium AGL Synthetic

Gearcase Lubricant

Capacity

948 ml 30 N-m 30 N-m

Transmission Oil Level

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level. Add

the recommended oil as needed. Do not overfill.

5. Reinstall the fill plug.

Torque to specification.

Fill Plug

Tor que

Drain Plug

Torq ue

Oil Level

MAINTENANCE

Drain Plug

Transmission Oil

Transmission Oil Change

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

5. Drain the oil into a drain pan.

6. Clean the drain plug.

7. Reinstall the drain plug.

Torque to specification. See page 80.

8. Add the recommended oil.

9. Reinstall the fill plug. Torque to specification. See page 80.

10. Check for leaks.

11. Discard used oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Demand Drive PLUS Fluid 275 ml 11-14 N-m 15 N-m

Torq ue

Drain Plug

Torq ue

Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:

• operation in ADC mode for prolonged periods

• constant ADC operation on hilly or mountainous terrain

• ADC is the primary mode of all-wheel-drive operation

TIP: If the front gearcase is makes excessive noise during ADC operation,

change the demand drive fluid. If the noise continues, please see your POLARIS dealer for service.

Use the recommended fluid. Use of other fluids may result in improper operation of components. See page 126 for the part numbers of POLARIS products.

Maintain the fluid level at the bottom of the fill hole threads.

Fluid Level

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

Drain the fluid into a drain pan.

5. Clean the drain plug.

6. Reinstall the drain plug. Torque

to specification. See page 82.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

MAINTENANCE

Active Descent Control (ADC) Fluid

The ADC fluid reservoir is located under the front box. The reservoir cap is yellow.

NOTICE: Change the ADC fluid every 25 hours if the ADC unit is exposed to

We recommend the use of POLARIS Demand Drive PLUS Fluid. See page 126 for the part numbers of POLARIS products.

Fluid Level

1. Position the vehicle on a level

2. Open the front box cover.

3. Remove the access panel

4. View the fluid level in the

5. Remove the cap and add the

6. Maintain the fluid level

7. Reinstall the access panel and

extreme use. Extreme use includes operation in ADC mode for prolonged periods or in environments that necessitate primary operation in ADC mode.

surface.

screws. Squeeze the outer edges of the panel inward to remove the panel.

reservoir.

recommended fluid as needed.

DO NOT use brake fluid.

between the minimum and maximum marks. Do not overfill.

secure the front box cover.

ADC Fluid

Reservoir

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on the ADC reservoir and

bleeder valves (one on each side of the differential).

3. Remove the reservoir cap and diaphragm assembly. Use a shop

towel or suction tool to remove debris from the fluid and reservoir.

TIP: Debris in the reservoir may result in inadequate bleeding and reduced per-

formance of the system.

4. Fill the reservoir to the maximum line with fresh recommended

fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow

fluid and trapped air to flow from the fitting. Close the valve when clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 N-m). Reinstall the valve caps.

8. Add fresh recommended fluid to the reservoir until the level is

between the minimum and maximum marks. Make sure the reservoir is free of debris.

9. Reinstall the cap securely. Clean up any drips or spills.

MAINTENANCE

Cooling System

Any time the cooling system has been drained for maintenance or repair, replace the coolant with a fresh mixture of antifreeze and water. Drain the cooling system every two years. Add fresh coolant.

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

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

Recovery Bottle Coolant

Some coolant level drop on new machines is normal, as the system is purging itself of trapped air. Add coolant as needed.

Check the coolant level in the radiator any time the recovery bottle has run dry. Add coolant as needed.

1. Check the coolant level when the fluid is cool.

2. Remove the left side panel. See page

94.

3. View the coolant level. Maintain the

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

4. Add coolant as needed.

5. Reinstall the side panel.

MAINTENANCE

Radiator

Cap

Cooling System

Radiator Coolant

Escaping steam can cause severe burns. Never remove the pressure cap while the engine is warm or hot.

1. Open the front box cover.

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

3. Remove the radiator pressure cap.

4. If coolant is not visible, slowly add coolant through the radiator filler neck.

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

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

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride. Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak brakes may indicate a fluid leak or low fluid level. A low fluid level may also mean that brake pads are worn and need to be replaced. Do not operate the vehicle with spongy or weak brakes. See your dealer for service.

Operating the Tractor with a spongy brake can result in loss of braking, which could cause an accident. Never operate the Tractor with spongy-feeling brakes.

If the fluid level is low add DOT 4 brake fluid only. See page 126 for the part numbers of POLARIS products.

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

Under normal operation, the diaphragm extends into the reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or severe injury. After opening a bottle of brake fluid, always discard any unused portion.

MAINTENANCE

Master

Cylinder

Indicator

Window

Full

Low

Brake Fluid

Hand Brake

The master cylinder is located on the left handlebar. Maintain the fluid level 6 mm below the top edge of the master cylinder. Do not overfill.

1. Position the vehicle on a

level surface. Make sure the handlebars are straight.

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

3. Add the recommended fluid as needed. Do not overfill.

MAINTENANCE

Brake Fluid

Foot Brake

The foot brake fluid reservoir is located under the seat.

1. Position the vehicle on a level surface.

2. Remove the seat.

3. View the fluid level in the

reservoir.

4. Remove the cap and add the

recommended fluid as needed.

5. Maintain the fluid level

between the minimum and maximum marks. Do not overfill.

6. Reinstall the reservoir cap.

7. Reinstall the seat.

Brake Fluid

Reservoir

Maximum Minimum

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by applying the foot brake. The handlebar brake is also hydraulic. Both brake systems are self-adjusting.

Brake Inspections

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

1. Always keep brake fluid at an adequate level. See page 88.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel

or spongy feel.

4. Check the friction pads for wear, dam-

age and looseness. Replace the pads when the friction material is worn to 1 mm.

5. Check the security and surface

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

1 mm

MAINTENANCE

Toe Alignment

Do not attempt to adjust alignment. All steering adjustments should be performed by an authorized POLARIS dealer.

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 3-6 mm toe out.

1. Position the vehicle on a level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire.

TIP: If available, you may use a

long straight-edge instead of string.

4. Measure the distance

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

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

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

service.

Stand

String

MAINTENANCE

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts and bolts. If loose nuts and bolts are found, see your POLARIS dealer for service before operating the vehicle.

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars, resulting in loss of control. Follow the adjustment procedures exactly, or see your POLARIS dealer for service.

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired height.

4. Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right.

5. Torque the front two bolts to 14-17 N-m, then torque the rear two bolts. A gap of up to 3 mm will remain at the rear of the clamp blocks.

14-17 N-m

Rear Spring

The rear shock absorber spring is adjusted by rotating the adjuster either clockwise or counter-clockwise to increase or decrease spring tension.

Adjuster

MAINTENANCE

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab.

3. With a firm motion, pull the panel outward to disengage the side panel from the grommet.

4. Pull the panel downward and rearward to remove it.

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

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

3. Remove the footwell.

Screws

Rivets

Throttle Cable Freeplay

Boot

Lock Nut

Adjuster

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far enough to expose the end of the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of freeplay is achieved at the thumb lever. Move the throttle lever back and forth while adjusting.

MAINTENANCE

1.6-3.2 mm

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it over the cable adjuster to its original position.

7. Engine RPM should not increase when steering is turned full left or

right. Readjust cable freeplay if this occurs.

MAINTENANCE

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 124 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 3 mm or less.

Front Wheel Hub Tightening

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

Wheel Nut Torque Specifications

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

3 mm

Nut Type Nut Torque

Lug Nut 41 N-m

PLUS 1/4 TURN

2-Piece Flange Nut 37 N-m

Tires

Wheel Removal/Installation

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Loosen the wheel nuts

slightly.

4. Place a suitable stand under

the footrest frame to raise the wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger tight.

9. Lower the vehicle to the ground.

10. Torque the wheel nuts to specification.

See torque chart on page 96.

MAINTENANCE

Main Filter

Pre-Filter

Fuel Filter

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

Air Filter

Always clean and replace the air and breather filters at the intervals outlined in the Periodic Maintenance Chart beginning on page 69.

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Remove the seat.

4. Release the air box

cover clips.

5. Remove the air

box cover.

6. Loosen the hose

clamp.

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry. Replace the fil-

ter if needed.

10. Reverse the steps to reinstall all components.

Polaris ATV Sportsman 500 Tractor INTL User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual