Polaris BRUTUS Owner's Manual

Download

BRUTUS™

BRUTUS™ HD

Owner's Manual

for Maintenance and Safety

PTO

WELCOME

Thank you for purchasing a POLARIS vehicle, and wel come to our world- wide family of POLARIS owners. We proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• BRUTUS

• RANGER® utility vehicles

• Victory® motorcycles®

• Low Emission Vehicles (LEVs) W e be lieve POLARIS sets a sta ndard of exce llence for all utility and recreat ional vehic les manufact ured in the worl d today. Many

years of experience have gone into the engineering, design, and development of your POLARIS vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyab le oper at ion of your vehicle, be su re to follow the instr uct io ns and recommendations i n th is owner’s manual . Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a Factory Certified Master Service Dealer® (MSD) Technician.

Your POLARIS dealer knows your vehicle best and is interes ted in your total satis fa ct ion . Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

™ utility vehicles

POLARIS is registered trademark of and BRUTUS is a trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales Inc. All information contained within this publication is based on the latest product information

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

The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 2013 BRUTUS Diesel Owner’s Manual P/N 9924341

Table of Con tents

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Features And Controls . . . . . . . . . . . . . . .18

Operation . . . . . . . . . . . . . . . . . . . . . . . . .34

Attachment Arm . . . . . . . . . . . . . . . . . . . .70

PTO System . . . . . . . . . . . . . . . . . . . . . . .74

Emission Control Systems . . . . . . . . . . . .76

Maintenance . . . . . . . . . . . . . . . . . . . . . . .77

Specifications . . . . . . . . . . . . . . . . . . . . .125

Polaris Products . . . . . . . . . . . . . . . . . . .128

Troubleshooting . . . . . . . . . . . . . . . . . . .130

Warranties. . . . . . . . . . . . . . . . . . . . . . . .131

Maintenance Log . . . . . . . . . . . . . . . . . .136

Index. . . . . . . . . . . . . . . . . . . . . . . . . . . .137

INTRODUCTION

WARNING

Failure to follow the warnings contained in this manual can result in severe injury or death.

A POLARIS BRUTUS is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating the vehicle. Keep this manual with the vehicle.

• Never permit a guest to operate this vehicle unless the guest has read this manual and all product labels.

• Always keep hands and feet inside the vehicle at all times

• The Polaris BRUTUS is not intended for on-highway use. Driver must be at least 16 years old with a valid driver’s license to operate. Passengers m us t b e a t least 12 years ol d a nd tall enough to sit with feet firmly on the floor. All SxS drivers should take a safety training course. Polaris recommends that drivers and passengers wear helmets, eye protection, and protective clothing, especially for trail riding and other recreational use. Always wear seat belts. Be particularly careful on difficult terrain. Never engage in stunt driving, and avoid excessive speeds and sharp turns. Riding and alcohol/drugs don’t mix. Check local laws before riding trails.

The BRUTUS is an off-r oad vehicl e. Familiari ze yourse lf 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 y our vehicle. Your safety is involved when these words and symbols are use d. Become familiar with their meanings before reading the manual.

Safety Symbols and Signal Words

The following signal words and symbols appear throughout this manual. Your safety and the safety of others 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 ind icates 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 hazar dous situat ion that, if not avoided, cou ld result in minor or moderate injury.

NOTICE

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

The Prohibition Safety Si gn indicates an ac tion NOT to tak e in order to avoid a hazard.

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

Vehicle Identification Numbers

Engine Serial Number

Key

Number

####

VIN

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 ignit ion key can be duplicated only by orde ri ng

INTRODUCTION

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:

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 i n like-new condition. Th e environ ment was

controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is depen-

dent on many factors, including:

Engine Serial Number:

Key Number:

• 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 worke r to reproduce typical work during mea surements

• Environmental factors such as ambient noise or temperature

Safety

PTO Warning

(If Equipped)

Discretionary

Warning

Age 16

Warning

Shift

Caution

To Start Engine / To Leave vehicle

Attachment Arm Warning

(If Equipped)

Seat Switch Warning

(If Equipped With PTO)

Towing Warning

Discretionary

Warning

Rotating Fan

Warning

Safety and Information Labels

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 any 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.

Safety Labels and Locations

Age 16 Warn ing

WARNING

NO OPERATOR UNDER 16 Operating this vehicle if you are under the age of 16 increases your

chance of severe injury or death. NEVER operate this vehicle if you are under age 16 and NEVER

operate this vehicle without a valid driver’s license.

7175566

To Start Engine / To Leave Vehicle

To Start Engine

• Gear Selector must be in PARK, NEUTRAL or travel control pedal must be in NEUTRAL.

• PTO must be OFF (If Equipped).

To Leave Vehicle

• Put gear selector in PARK.

• STOP engine.

7179357

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.

7172674

Seat Switch Warning

WARNING

• Check that seat switch is properly installed and functions correctly.

• Replace switch and components if damaged or missing.

7179343

SAFETY

Discretionary Warning

WARNING

Improper vehicle use can result in Serious Injury or Death. NEVER Operate:

• At speeds too fast for your skills or the conditions.

• After or while using Alcohol or Drugs.

• On hills steeper than 15 degrees 15°.

• On public roads, a collision can occur with a another vehicle.

• With passengers under age twelve or who cannot comfortably reach the floor and hand holds.

• With unapproved accessori es - they may seriously affect stability.

ALWAYS:

• Wear your seat belt. Vehicle rollover could cause severe injury or death.

• Wear eye protection and keep hands and feet in vehicle at all times.

• Reduce speed and use extra caution when carrying passengers.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

• Make sure passenger reads and understands all safety signs.

• Watch for branches or other hazards that could enter vehicle.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

7179169

SAFETY

Safety Labels and Locations

Attachment Arm Wa rning

WARNING

Avoid Serious Injury Or Death.

• Do not excee d attachment arm rated capacity.

• Keep bystanders away. No riders on attachment.

• Keep hands and body from under attachment.

• Do not modify the attachment arm o r use una pprove d att achme nts . 7179168

Rotating Parts Warning

Rotating Parts Can Cause serious Injury Or Death

• Keep PTO shield and all guards in place.

• Keep away from moving parts.

• Keep bystanders away.

• Do not exceed the PTO speed of 2000 RPM

See Owner’s Manual For More Instructions.

7179185

Rotating Fan Warning

WARNING

Avoid Serious Injury Or Death . Do not operate with shields removed. Do not modify.

7179166

Maximum Trailer Weight Warning

WARNING

Towing An Improperly Loaded Trailer Can Cause Loss Of Control Resulting In Serious Injury Or Death.

Maximum Tongue Weight: 150 lbs. (68 kg) Maximum Tow Weight: 2000 lbs. (907 kg) See Owner’s Manual For More Instructions.

7179167

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

WARNING

FALLING OFF CARGO BOX CAN CAUSE SERIOUS INJURY OR DEATH

• Never carry riders in cargo box. OVERLOADING OR IMPROPER TIRE PRESSURE CAN CAUSE

TIPPING OR LOSS OF CONTROL RESULTING IN SERIOUS INJURY OR DEATH.

• Never exceed load capacities.

• Reduce speed and allow greater distance for braking when carrying cargo.

• Carrying tall, off-center, or un-secured loads will increase your risk of losing control. Center and secure loads as low as possible in box.

• Reduce speed and cargo on rough or hilly terrain.

• Check for proper tire pressure.

BRUTUS BRUTUS HD BRUTUS HDPTO

MAXIMUM CARGO BOX LOAD 1250 lbs.

ATTACHMENT ARM RATED CAPACITY 500 lbs.

TIRE PRESSURE IN PSI (KPa) MAXIMUM WEIGHT CAPACITY INCLUDES WEIGHT OF OPERATOR,

PASSENGER, CARGO AND ACCESSORIES

Read Operation and Maintenance Manual for more detailed loading information.

(567 kg)

FRONT 10 (69) REAR 20 (138)

1750 lbs.

(794 kg)

1250 lbs.

(567 kg)

(225 kg)

FRONT 20 (138)

REAR 20 (138)

2000 lbs.

(907 kg)

SAFETY

1250 lbs.

(567 kg) 500 lbs.

(225 kg)

FRONT 20 (138)

REAR 20 (138)

1750 lbs.

(794 kg)

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding a POLARIS vehicle. Wear protective clothing for comfort and to reduce the chance of injury.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles. 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. Do not ride a POLARIS vehicle with bare feet.

Clothing

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

Operator Safety

WARNING

SAFETY

Serious injury or death can result if you do not follow these instructions and proc edures , which are outl ined i n further det ail within your owner's manual.

• Read this manual and all labels carefully. Follow the operating procedures described.

• Never allow anyo ne unde r age 16 t o operat e this ve hicle an d never allow anyone without a valid driver's license to operate this vehicle.

• Do not carry passengers until you have at least two hour s o f driving experience with this vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.

• The driver and all passengers must wear eye protection and seat belt at all times. All riders should also wear long sleeves, long pants and sturdy over-the-ankle boots.

• Always keep hands and feet inside the vehicle at all times.

• Always keep both hands on t he ste ering whe el and b oth feet on the floorboards of the vehicle during operation.

• Never permit a gu est to operate thi s vehicle unless the gue st has read this manual and all product labels.

• To reduce tipover risk, be especially careful when encountering obstacles a nd slop es and when b raking on hills or during turns.

• This vehicle i s for of f road use onl y . Never operate on pub lic roads. Always avoid paved surfaces.

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

• Never operate at exce ss ive speeds. Always travel at a speed proper for the terrain, visibility and operating conditions, and your experience.

• Never attempt jumps or other stunts.

• Always inspec t t he vehicle before each use to make sure it' s in safe operating condition. Always follow the inspection procedures described in this manual.

• Always travel slowly and use extra caution when operating on unfamiliar terrain. Be alert to changing terrain.

• Never operate on excessively rough, slippery or loose terrain.

• Always follow proper procedures for turning. Practice turning at slow speeds before attempting to turn at faster speeds. Never turn at excessive speeds.

• Always have this vehicle checked by an authorized POLARIS dealer if it has been involved in an accident.

• Never operate this vehicle on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hill s.

SAFETY

Operator Safety

• Always follow proper procedures for climbing hills as described in this manual. Check the terrain carefully before attempting to climb a hill. Never climb hills with excessively slippery or loos e surf aces. Nev er mo ve the t ravel control pedal suddenly, make sudden changes of direction or make sudden gear change s. Never go ove r the top o f a hill a t high speed.

• Always follow the proper procedures outlined in this manual for traveling downhill and for braking on hills. Check the terrain carefully before descending a hill. Never travel downhill at high speed. Avoid going downhill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight down the hill where possible.

• Always check for obstacles before operating in a new area. Never atte mpt to operate over large o bstacles such as roc ks or fallen trees. Always follow the proper procedures outlined in this manual when operating over obstacles.

• Always be careful of skidding or sliding. On slippery surfaces such as ice, travel slowly and exercise caution to reduce the chance of skidding or sliding out of control.

• Never operate your ve hicle in f ast- flowin g water or i n water deeper than that specified in this manual. Wet brakes may have reduced stoppi ng abilit y. Test your brakes aft er leavi ng water. If necessary, apply them lightly several times to let friction dry out the pads.

• Always be sure there are no ob stacles or peopl e behi nd your vehicle when opera ting i n reve rse. When it's safe to procee d in reverse, move slowly. Avoid turning at sharp angles in

reverse.

• Always use the proper size and type of tires specified in this manual. Alw ays maintain proper tire pressure as specified on safety lab els.

• Never modify this vehicle through improper installation or use of accessories.

• Never exceed the s tated load ca pacity for th is vehicle. Ca rgo should be properly distributed and securely attached. Reduce speed and follow the instructions in this manua l for hauling cargo, with attach ments insta lled or pull ing a traile r. Allow a greater distance for braking. Keep the attachment arm low (if equipped) and slow down when turning.

• Disengage PTO (if equipped), put the gear selector in PARK, stop the engine and make sure all rotating components are stopped before exiting utility vehicle.

• Always stop the engine before refueling. Remove flammable material co ntainers f rom the box before fi lling them wi th fuel. Make sure the refueling area is well ventilated and free of any source of flame or sparks. Fuel is extremely flammable. See page 38 for fuel safety warnings.

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

FOR MORE INFORMATION ABOUT SAFETY, call POLARIS at 1-800-342-3764.

Operator Safety

WARNING

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS BRUTUS any equipment that may increase the speed or power of the ve hicle, or make any other modification s to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

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

The addition of certain accessories, including (but not limited to) mowers, blades, tires, spraye rs, or large racks, may change the handling characteristics of the vehicle. Use only POLARIS-approved accessories and attachments, and familiarize your self with their function and effect on the vehic l e.

Failure to operate the BRU TUS properly can result in a collis ion , loss of control, accident or overturn, which may result in serious injury or death. Heed all safety w arnings outlin ed in this sec tion of the ow ner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

SAFETY

Age Restrictions

This vehicle is an ADULT VEHICLE ONL Y. NEVER operate this vehicle if you are under age 16 and NEVER operate wi tho ut a valid driver’s license.

No person under the age of 12 may ride as a passenger in this vehicle. Any passenger must be able to comfortably reach the floor and hand holds.

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.

All operators must read and understand the Own er' s Ma nua l and all warning and instruction labels before operating the vehicle.

SAFETY

Operator Safety

Using Alcohol or Drugs

Operating the vehicle afte r consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.

Never drink alcohol or use drugs or medications before or while operating this vehicle.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of serious injury in the event of an accident or sudden stop. Riders must wear seat belts at all times. Seat belts reduce the severity of injury in the event of a sudden stop or accident. Always make sure the seat belts are secured for both the operator and passengers before riding.

Always follow these guidelines:

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

Passenger and/or cargo exceeds half the maximum weight capacity 1. Slow down. Operating in rough terrain Operating over obstacles Climbing an incline Towing Operating with attachments installed

Protective Eyewear

Riding in this vehicle without wearing protective eye wear increases the risk of a serious injuries in the event of an accident.

Operator and all passengers must always wear approved eye protection (goggles).

Operating With a Load on the Vehicle

The weight of both cargo and passengers impacts vehicle operation. 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 exceed vehicle weight capacities. The vehi cle’ s maxim um

weight capacity is listed in the specifications section of this manual and on a label on the vehicle. When more passenger weight is added, cargo weight may need to be reduced accordingly.

• The recommended tire pressures are listed in the specifications

section of this manual and on a label on the vehicle.

2. Verify tire pressure.

3. Use extra caution when operating.

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 inspect your BRUTUS before each use to make sure it's in safe operating condition.

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

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness o r death i n a sh ort time . Nev er st art the engin e or let it run in an enclosed area.

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

Operating a Damaged Vehicle

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

Operating at Excess ive Speeds

Operating this vehicle at excessive speeds increases the operator's risk of losing control. Alway s operat e at a speed that's appropria te for the terrain, the visib ility and operating co ndi tio ns, your skills and your passengers’ skills.

SAFETY

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn. Always follow proper procedures for turning. Never turn abruptly or at sharp angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster speeds.

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 could result in loss of control and accident or overturn.

Avoid operating the vehicle on pavement. If it's unavoidable, travel slowly and avoid sudden turns or stops.

SAFETY

Operator Safety

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 roa ds . In som e are as it' s unlaw fu l to ope rate this vehicle on public streets, roads and highways.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn. Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an ac ci den t or overturn. Unfamili ar te rrain may contain hidden rocks, bumps, or holes that could cause loss of control or overturn.

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

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively slippery surfaces. Always reduce speed and use additional caution when operating on

slippery surfaces.

Improper Hill Climbing

Climbing hills imp roperly can ca use loss of co ntrol or vehicl e overturn. Always follow proper procedures for clim bin g h ill s as described in the owner's manual. See page 53.

Stalling While Climbing a Hill

Stalling or rolling backwards while climbing a hill could cause an overturn. Always maintain a steady speed when climbing a hill.

If all forward speed is lost (engine running):

• Use the travel control pedal to slowly back the vehicle straight downhill.

• If necessary, apply brake pressure to control speed.

If all forward speed is lost (engine not running):

• Apply the brakes and attempt to restart the engine.

• If engine will not restart, place transmission in neutral and slowly allow the vehicle to roll straight downhill while applying brake pressure to control speed.

Operator Safety

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 Frozen Bodies of Water

Severe injury or dea th c an re sul t i f th e vehicle and/or the op era tor fall through the ice. Never operate the vehicle on a frozen body of water unless you have first v erified that the i ce is suf fi cientl y thi ck t o sup port the weight and moving force of the vehicle, yo u and your pass engers, and your cargo, t ogether with any other v ehicl es 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.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which cou ld re sult in an accident o r ov ert urn. Always remove the ignition key when the vehicle is not in use.

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.

SAFETY

Attachment Arm System (If Equipped)

The dealer explains the capabilities and restrictions of the BRUTUS utility vehicle, attachment and accessories for each application. The dealer demonstrates the safe operation according to Polaris instructional materials, which are also available to operators. The dealer can also identify unsafe modifications or use of unapproved attachments and accessories. The attachments and buckets are designed for an attachment arm Rated Capacity. They are designed for secure fastening to the BRUTUS utility vehicle. The user must check with the deale r, or POLARIS literature, to determine safe lo ads of materials of specified densities for the vehicle - attachment combination.

Safety Rules For Power Take-Off (PTO) Driven Attachments (If Equipped)

• Keep PTO shields and all guards in place. Replace damaged or

missing shields and guards before operating.

• Follow warnings and instructions on machine signs (decals).

Replace damaged or missing decals.

• Do not wear loose or bulky clothing around the PTO or other

moving parts.

• Keep bystanders away from PTO driven equipment, and never

allow children near machines.

• Read and understand the manuals for the PTO driven equipment

and be aware of safe operating procedures and hazards that may not be readily apparent.

• Always walk around equipment to avoid coming near a turning

PTO driveline. Stepping over, leaning across or crawling under a turning PTO driveline can cause entanglement.

• Position the machine and attachment correc tl y to prevent driveline

stress.

• Use caution when raising PTO driven attachment. Excessive

driveline angle can reduce driveline service life.

FEATURES AND CONTROLS

Front Bumper/

Brush Guard

Radiator

ROPS / OPS

Cab Frame

Console

Hip Bar

Cargo Box

Fuel Tank Cap

Tailgate Latch

Release

Receiver Hitch

Muffler

(Spark Arrester)

Tailgate

Storage Compartment

Under Seats

Headlights

Center Console

(Model HD and HD

PTO Only)

Attachment Arm

(Model HD and HDPTO Only)

PTO

(Model HDPTO Only)

Taillights

Component Locations

Not all models come with all features. Refer to the specifications section on page 125.

Switches and Indicator Lights

Ignition

Switch

Light Switch

AWD/Differential Switch

Power Lift Assist Switch

(If Equipped)

Blank Switch Op enings -

Available For Accessories

HVAC Switches

(If Equipped)

STARTOFF

Ignition Switch

The ignition switch is a three-position, key-operated switch. The key can be removed from the switch in the OFF position.

OFF The engine is off. Electrical circuits are off, except Acc,

ON Electrical circuits are on. Electrical equipment can be

START After the wait-to-start indicator turns off, turn the key to

12V.

used.

the START position to engage the electric starter. The key returns to the ON position when released.

FEATURES AND CONTROLS

Switches and Indicator Lights

HIGH

OFF

LOW

AWD

Differential Lock

Differential Unlock

Fan

A/C

On-Off

Temp

Control

Wiper

Switch

Washer

Switch

Light Switch

The ignition switch must be in the ON position to operate the headlights.

Press the top of the rocker switch toward the dash to place the headlights on high beam.

Move the rocker switch to the center position to place the hea dl ights on low beam.

Press the bottom of the rocker switch to turn off the headlights.

AWD/Differential Lock Switch

The AWD/Differential Switch has three positions:

• All Wheel Drive (AWD)

• Differential Lo ck (2WD)

• Differential Unlock Press the top of the rocker

switch to eng age All Wheel Drive (AWD). See page 66 for operating instructions.

Move the rocker switch to the center position to lock the differential and operate in rear wheel drive. Press the bottom of the switch to unlock the differential and allow the two rear drive wheels to operate independently. See page 66 for differential lock operating instructions.

HVAC Switches (If Equipped)

If equipped with a Cab with HVAC (Heat and Air Conditioning):

• Fan Switch (OFF-LowMed-High)

• Air Conditioning (Press top of switch to turn Air Conditioning ON, bottom for OFF)

• Temperature Control Switch (Rotate clockwise to increase temperature, counterclockwise to decrease)

Wiper Switch (If Equipped)

If equipped with a cab with a wiper, the front wiper swit ch is located on the wiper motor cover at the top of the front window:

• Wiper Switch (OFF-LowHigh)

• Washer Switch (Press and hold top of switch to activate window washer)

Console

Cup Holder

12V Auxiliary

Outlet

Mode

Button

Storage

Tray

Instrument

Cluster

Gear Selector

(Shifter)

Steering

Wheel

Storage

Compartment

Cup Holder

FEATURES AND CONTROLS

Auxiliary Outlet

The 12-volt receptacles have spade connections on the back that may be used to power an auxiliary light or other optional accessories or lights. The connections are behind the console, under the dash.

Mode Button

The button located on the instrument cluster is used to toggle through mode options. See pages 27-33.

Gear Selector

Use the gear selector to shift gears. Low gear is the primary driving range for the BRUTUS. High gear is intended for use on hard-packed surfaces with light loads. To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

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

Tip: Maintaining shift linka ge adjustmen t is important to assure proper

the vehicle is moving could cause transmission damage. Always shift when the vehicle is stationary and the engine is at idle.

transmission function. See your dealer if you experience any shifting prob lems.

FEATURES AND CONTROLS

Console

Adjustable Steering Wheel

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

Lift and hold th e adjust ment lever toward you while moving the steering wheel upward or downward. Release the lever when the steering wheel is at the desired position.

Center Console (For Models HD and

PTO Only)

Joystick - Attachment Arm

Movement of the joystick (Item 1) controls the lift and tilt functions of the attachment arm and the PROTACH attachment system. See Page 44.

Engine Speed Control Lever

The engine speed control lever (Item 2)controls engine RPM. This is used to set engine RPM separately from the travel speed when using attachments. See Page 47.

Power T ake-Off (PTO)

The front PTO (Item 3) is available on model HDPTO only. The PTO has a rated speed of 2000 RPM. The PTO is used to power some attachments. See page 68.

WARNING! Do NOT exceed the rated attachment PTO speed. Stay clear of rotating driveline. Keep bystanders away. Keep PTO shields and all guards in place. Disengage PTO, put the gear selector in PARK, stop the engine and make sure all rotating components are stopped before exiting utility vehicle. Do NOT service the utility vehicle or attachment with the PTO engaged. Do NOT service the attachment in a raised position unless properly blocked and with all rotating components stopped. Disengage PTO for road travel.

FEATURES AND CONTROLS

Joystick Lock Switch

The joystick lockout switch (Item 4) is used to active or lockout the joystick functions. The joystick should be lockout when no attachments are instal led. This will keep the joystick from accidentally being activated. See Page 44.

Tilt Lock Switch

The tilt lockout switch (Item 5) locks out the tilt function. See Page 44.

Tip: When operating PTO driven attachments, the tilt lockout switch

will automatically activate. Using the attachment with the tilt locked out will limit the possibility of tilting the attachment while the PTO shaft is turning and putting stress on the PTO driveline u-joints. Before engaging the PTO system, tilt the attachment to the desired operating position. See your attachment Owner’s Manual for detailed information.

Front Auxiliary Hydraulic Switch

The front auxiliary hydraulic switch (Item 6) controls hydraulic flow to the front male and female coupler for attachment operation. See Page 45.

FEATURES AND CONTROLS

ROPS / OPS

Travel Control

Pedal

Brake

Pedal

Rollover Protective Structure (ROPS) / Occupant Protective Structure (OPS)

The Rollover Protective Structure (ROPS) on this vehicle meets OSHA 1928.53 rollover performance requirements. The Occupant Protective S t ruc tur e (OPS) on this vehicle meets ANSI/OPEI B71.9-2012 occupant requirements. Always have your authorized POLARIS dealer thoroughly inspect the ROPS / OPS if it ever becomes damaged in any way.

No device can assure occupant protection in the event of a rollover . Always follow all safe operating practi ces out li ned 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.

Storage Compartments

A storage compartment is located under both the driver’s and operator’s seat.

Trailer Hitch Bracket

This vehicle is equipped with a receiver hitch bracket for a trailer hitch. To avoid injury and property damage, always heed the warnings and towing capacities outlined on pages 61.

Brake Pedal

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

Travel Control Pedal

The travel control pedal is used to control the forward and backward movement of the utility vehicle. The farther the pedal is pressed, the faster the travel speed.

Press the toe of the pedal for forward travel, press the heel of the pedal for backward travel.

Seat Removal

Seat

Switch

Harness

Model HD

PTO Only

Buckle

Latch Plate

Pull up on the rear of the seat and tilt it toward the front of the vehicle. In stall the seat by sliding the tabs into the front of the seat base. Push down firmly on the rear of the seat until the pins are full y s eat ed into the gro mmets .

Tip: For Model HDPTO; a seat switch is

located under the operator’s seat. Set the seat aside if possible to avoid disconnecting the seat switch. If the seat switch is disconnected, the harness must be secured in it’ s origin al positio n to avoid harness damage.

Seat Belt s

This POLARIS vehicle is equipped with three-point lap and diagonal seat belts on all external seats.The center seat is equipped with a lap-style seat belt. Always make sure the se at belts are secured for all riders befo re operating.

WARNING! Falling from a moving vehicle c ould resu lt in serious injury or death. Always fasten your seat belt securely before operating or riding in the BRUTUS.

FEATURES AND CONTROLS

To wear the seat belt properly, follow this procedure:

1. For 3-point belts, 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. For lap style belts, place the belt across your lap as low on your hips as possible. Make sure that the belt is not twisted.

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

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

Tip: The center belt must be tightened manually by pulling on the

strap.

4. To release the seat belt, press the square red button in the

buckle's center.

FEATURES AND CONTROLS

Seat Belt s

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 soa p and wate r. Do not use bleach, dye or household detergents.

Instrument Cluster

Your vehicle is equipped with an instr ument clus ter that senses vehicle speed from the transmission. In addition to showing vehicle speed, the s peedometer needle fl as hes when a warning condition exists.

NOTICE: High water pressure may damage components. Wash the

Rider Information Center

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

chemicals, will damage the instrument cluster 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 fuel that splashes on the instrument cluster.

The rider information display is located in the instrument cluster. All segments will light up for 1 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.

1. Vehicle Speed Display - Analog display of vehicle speed

in MPH or km/h.

2. Information Display Area - Odometer / Tri p Meter /

Tachometer / Engine Temperature / Engine Hours / Service Info - LCD display of the service hour interval,

total vehicle miles or km., total engine hours, a trip meter, engine RPM and engine temperature.

FEATURES AND CONTROLS

Instrument Cluster

3. MPH / KM/H Display - MPH is displayed when the instrument cluster is in the Standard mode. KM/H is dis- played when the instrument cluster is in the Metric mode.

4. High Beam Indicator - LED icon illuminates whenever the Headlam p switch is in the high beam position.

5. Fuel Level Indicator - LCD bar graph indicating current fuel level. All segments will flash when the last segment is cleared indicating a low fuel warning.

6. Clock / PTO RPM - Displays current time in either 12hour or 24-hour formats. When the PTO is engaged, PTO RPM will be indicated instead of the clock.

7. Engine / Hydraulic Fluid Temperature Indicator - LED icon illuminates when the ECM determines the engine is overheating. The indicators will initially flash to indicate the engine is overheating. The indicators will stay lit and not flash if a severe overheating condition exists.

8. PTO Indicator - PTO is engaged when this is illuminated. PTO RPM will be displayed in the Clock field (6) ONLY when engine RPM is displayed in the Information Display Area (2).

9. Check Engine MIL - Illuminated when the ECM has detected a Diagnostic Trouble Code in the engine management system.

10. Unit Lock - N/A on this model.

11. Hour Meter - Illuminates when the dis play (2) i s showing hours.

12. Low Oil Pressure Indicator - LED icon illuminates low

engine oil or hydraulic fluid pressure is sensed.

13. Gear Position Indicator - Displays gear selector position. H = High

L = Low N = Neutral P = Park

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

14. Power Steering System MIL - N/A on this model.

15. Glow Plug Indicator - Illuminated when the glow plugs

are active. Light goes out when the engine is ready to start.

16. Seat Belt Indicator - LED ic on illuminate s for 10 secon ds

when the key is turned to the ON position. The lamp is a

reminder to the operator to ensure all riders are wearing

seat belts before operating the vehicle.

17. AWD/TURF Indicator - Illuminate to ind icate how many

drive wheels are active. This will tell you if you are in

AWD, 2WD, or Turf.

18. ADC Indicator - N/A on this model.

19. Service Interval Indicato r - Preset at the factory and

adjustable by the user, a flashing wrench symbol alerts the

operator that the preset service interval has been reached

and maintenance should be performed. The wrench icon

will flash for 10 seconds upon start-up once it reaches 0.

20. Unit of Measurement - Indicates the measurement (Trip

1, Trip 2, KM, MI, RPM) being displayed in the Informa-

tion Display Area (2).

Instrument Cluster

Information Display Area

The LCD portion of the instrument cluster is the information display area which displ ays the f ollowi ng infor mat ion: odometer, trip meter, RPM, battery voltage, engine temperature, air temperature, engine hours , tro ubl e code s, service interval, and clock.

Units of Measurement

Distance Miles (MPH) Kilometers (KM/H) Temperature Fahrenheit Celsius Time 12-Hour Clock 24-Hour Clock

T o change bet ween S tandard and Metri c units of mea surement, follow these steps:

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.

FEATURES AND CONTROLS

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

5. Repeat the procedure to change rema ining displ ay setting s.

FEATURES AND CONTROLS

Instrument Cluster

Odometer

Engine Hours

The odometer records and displays the total distance traveled by the vehicle. The odometer can not be reset.

Trip Meter

The trip meter records the miles tr aveled by the vehicle on each trip. To reset the t rip meter:

1. Toggle the MODE button to TRIP 1.

2. To reset to 0, push and hold the MODE button until the distance display changes to 0.

Engine hours are logged anytime the engine is running. Total hours can not be reset.

Tachometer (RPM)

Engine RPM can be displayed digitally. PTO RPM, when engaged, is indicated after the PTO icon.

Instrument Cluster

Engine Temperature

FEATURES AND CONTROLS

Clock

Engine temperature can be displayed in F° or ° C. Refer to “Units of Measurement” to change the format.

The clock displays the time in a 12-hour or 24-hour format. Refer to “Units of Measurement” to change the format (Standard 12-hour / Metric-24 hour). To set the clock, follow these steps:

1. Toggle the MODE button until the odometer is displayed.

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.

FEATURES AND CONTROLS

Instrument Cluster

Battery 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 a high electrical load is applied (lights, cooling fan or other accessories).

Battery Voltage Low

If battery voltage drops below 11 volts, a warning screen will display “Lo” and provide the present battery voltage. If voltage drops below 8.5 volts, LCD backlighting and icons will turn off.

Battery Voltage High

If battery voltage rises above 15 volts, a warning screen will display “OV” and provide the present battery voltage. If voltage rises above 16.5 volts, LCD backlighting and icons will turn off.

Programmed Service Interval

The initial factory service interval setting is 50 hours. Each time the engine is start ed, the engine hours are sub tracted from the service interva l hours. When the ser vice inter val reaches 0, the LCD wrench icon will flash for approximately 10 seconds each time the engine is started.

To change the hour setting or reset the function, follow these steps:

1. Toggle the MODE button until the wrench icon is displayed in the information area.

2. Press and hold the MODE button unti l the i nformat ion dis play area begins to flash.

3. Toggle the MODE button to increase the service interval hours in 5 hour increments to a maximum of 100 hours.

4. To turn off the service interval function, toggle the MODE

button until “OFF” is displayed.

Instrument Cluster

Check Hydraulic

Indicates too low of hydraulic oil pressure which is likely caused by a plugged or too high of hydraulic oil temperature. The Oil or Temperature l ight will illuminate along with this message.

Check Engine / Trouble Code Display

The diagnostic mode i s acces sible only when the che ck engi ne MIL has been activated

Use the following procedure to display diagnostic trouble codes that were acti vated durin g curr en t ign ition cycl e caus ing the MIL to illuminate. Diagnostic trouble codes will remain stored in the gauge (even if MIL turns off) until the key is turned off.

FEATURES AND CONTROLS

1. If the trouble codes are not displayed, use the MODE button to toggle until “CK ENG” displays on the information display area.

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

3. A set of three numbers will appear in the information area.

4. The first number (located far left) can range from 0 to 9. This number represents the total number of trouble codes present (example: 2 means there are 3 codes present).

5. The second number (located top right) can be 2 to 6 digits in length. This number equates to the suspected area of fault (SPN).

6. The third number (located bottom right) can be 1 to 2 digits in length. This number equates to t he f au lt mode (FMI).

7. See your dealer for Diagnostic Trouble Codes.

8. If more than one code exists, press the MODE button to advance to the next trouble code.

9. To exit the diagnostic mode, press and hold the MODE button or turn the ignition key OFF once the codes are recorded.

OPERATION

WARNING

Failure to operate the v ehi cl e properly can resul t in a collision , lo ss o f control, accident or overturn, which may result in serious injury or death. Read and understand all safety warnings outlined in this owner’s manual.

Break-In Period

The break-in period for your new vehicle is the first 50 hours of operation. No single a ct ion on your part is as impor ta nt as a proper break-in per iod . Car ef ul treatment of a new e ngi ne wi ll result in more efficient performance and longer life for the engine.

New Engine Break-In

1. Fill the fuel tank with the recommended fuel. See page 36.

2. On the in itial engine start-up, allow the engine to idle for approximately 15 minutes. Check for proper engine oil pressure, diesel fuel leaks, engine oil leaks, coolant leaks, hydraulic leaks and proper operation of the indicators and gauges.

3. During the first hour of operation, vary engine speed and the load on the engine. Short periods of maximum engine speed and load are de sirable. Avoid prolonged operatio n at minimum or maximum engine speeds and loads for the next 4 to 5 hours.

4. During the break-in period, carefully observe the engine oil pressure, engine temperature and hydraulic fluid temperature.

5. Check the engine oil, engine coolant and hydraulic fluid level frequently during the break-in period. Perform regular checks on areas outlined on the daily pre-ride inspection checklist. See page 35.

6. Change both the engine oil and the filter at 50 hours.

7. Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours thereafter.

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 Ensure proper operation. 24, 101 Brake fluid Ensure proper level. 101 Front and Rear suspension Inspect, lubricate if necessary. 119 Seat Belts Check length of belt for damage, check latches for proper operation. 26 ROPS/OPS Check condition of ROPS/OPS and mounting hardware. 26 Steering Ensure free operation. 103 Tires/wheels/fasteners Inspect condition and pressure. Inspect, ensure fastener tightness. 112 Safety Signs (Decals) Check for damaged or missing signs (decals). Replace any signs that are damaged or missing. Frame nuts, bolts, fasteners Inspect, ensure tightness. Fuel and oil Ensure proper levels. 39, 88 Coolant level Ensure proper level. 92 Coolant hoses Inspect for leaks. Travel Control Pedal Ensure proper operation. 24 Indicator lights/switches Ensure operation. 19 Air filter, pre-filter Inspect, clean and replace as needed. 95 PTO (If Equipped) Inspect splines, guards, shields and hardware, ensure tightness, replace damaged parts. 51 Brake light/tail lamp /Headlamp Check operation, apply POLARIS dielectric grease when lamp is replaced. 102, 114 Heater/Air Conditioning Filter Clean and replace filter as needed during heating and cooling season. 106

OPERATION

Fuel Recommendations

NOTICE: For the best engine performance, to prevent engine

POLARIS recommends the follow ing diesel fuels for use in this vehicl e:

•Low Sulfur

• Ultra Low Sulfur #2

• #1 Diesel Fuel containing no more than 5% bio-diesel (see page 37)

See page 39 for cold we ather fu el blend recommendati ons. For more information about recommended diesel fuels and the consequences of using bio-diesel fuel exceeding 5% bio-diesel, see Additional Technical Fuel Requirements below.

Diesel fuel should comply with the following world-wide specifications.

Diesel Fuel Specification Location

ASTM D975 No. 1D S15, S500 No. 2D S15, S500

EN590:96 European Union ISO 8217 DMX International BS 2869-A1 or A2 United Kingdom JIS K2204 Grade No. 2 Japan KSM-2610 Korea GB252 China

damage and to comply with EPA/CARB warranty requirements, use ONLY the recommended diesel fuels. Use only CLEAN diesel fuel.

USA

Additional Technica l Fuel Requirements

• The fuel cetane number should be equal to 45 or higher.

• The sulfur content must not exceed 0.5% by volume. Less than 0.5% is preferred. Espe cially in th e U.S.A. and Canada, Low Sulfur (300 to 500 ppm (mg/kg) or Ultra Low Sulfur fuel should be used.

• Bio-Diesel fuels: see pages 37-38.

• NEVER mix ker osene, used engin e oil or residual fuels with diesel fuel.

• Water and sediment in the fuel should not exceed 0.05% by volume.

• Keep the fuel tank and fuel-handling equipment clean at all times.

• Poor quality fuel can reduce engine performance and/or cause engine damage.

• Fuel additives are not recommended. Some fuel additives may cause poor engine performance.

• Ash content must not exceed 0.01% by volume.

• Carbon residue content must not exceed 0.35% by volume. Less than 0.1% is preferred.

• Total aromatics content should not exceed 35% by volume. Less than 30% is preferred.

• PAH (polycyclic aromatic hydrocarbons) content should be below 10% by volume.

• Metal content of Na, Mg, Si and Al should be equal to or lower than 1 mass ppm (test analysis method JPI-5S-44-95) .

• Lubricity: Wear mark of WS1.4 should be Max. 0.018 in. (460µm) at HFRR test.

Fuel Recommendations

Bio-Diesel Fuels

In Europe and in the United States, as well as some other countries, non-mineral oil based fuel resources such as RME (Rapeseed Methyl Ester) and SOME (Soybean Methyl Ester), collectively known as FAME (Fatty Acid Methyl Esters), are being used as extenders for mineral oil derived diesel fuels.

YANMAR approves the use of bio-diesel fuels that do not exceed a blend of 5% (by vol ume) of FAME with 95% (by volume) of approved mineral oil deriv ed die sel fu el. Suc h bio- diesel fuels are known in the marketplace as B5 diesel fuels.

These B5 diesel fuels must meet certain requirements:

1. The bio-fuels must meet the minimum specifications for the country in which they are used.

• In Europe, bio-diesel fuels must comply with the European

Standard EN14214.

• In the United States, bio-diesel fuels must comply with the

American Standard ASTMD-6751.2.

2. Bio-fuels should be purchased only from recognized and

authorized diesel fuel suppliers.

OPERATION

Precautions and concerns regarding the use of bio-fuels:

1. Free methanol in FAME may result in corrosion of aluminum and zinc FIE components.

2. Free water in FAME may result in plugging of fuel filters

and increased bacterial growth.

3. High viscosity at low temperatures may result in fuel

delivery problems, injection pump seizures and poor injection nozzle spray atomi za ti on.

4. FAME may have adverse effects on some elastomers (s eal

materials) and may result in fuel leakage and dilution of the engine lubricating oil.

5. Even bio-diesel fuels that comply with a suitable standard

as delivered will require additional care and attention to maintain the quality of the fuel in the equipment or other fuel tanks. It is important to maintain a supply of clean, fresh fuel. Regular flushing of the fuel system and/or fuel storage containers may be necessary.

6. The use of bio-diesel fuels that do not comply with the

standards as agreed to by the diesel engine manuf acturers and the diesel fuel injection equipment manufacturers, or bio-diesel fuels that have degraded as per the precautions and concerns above, may affect the warranty coverage of your engine.

OPERATION

Fuel Recommendations

Bio-Diesel Fuels

B6 To B20 Bio-diesel Fuel Blend Usages

B6 to B20 bio-diesel is not approved for this POLARIS application.

Approved Engines

Only the YANMAR TNM engine series listed below may operate with bio-diesel fuel concentrations up to B5 for POLARIS applications

NOTICE: Do not exceed bio-diesel fuel ble nd B5 for thi s POLARIS

application.

•3TNM72

Approved Fuel

NOTICE: Raw pressed vegeta ble oils are no t con si dere d bi o-di es el,

and are unacceptable for use as fuel in any concentration in YANMAR engines.

Bio-diese l fuel blends up to B5 must comply with the following standards:

• EN14214 (European standard) and/or ASTM D-6751 (American standard).

• All applicable engines may operate with bio-diesel fuel up to a maximum B5 (5% bio-diesel blend) concentration.

Operating Conditions with B5 Bio-diesel Fuel Blends

Engine Warranty

Damages, performance or service concerns determined to be caused by the use of bio-diesel fuel not meeting the specifications outlined above are not considered to be defects in material or factory workmanship and are not covered under warranty. The same applies to damages or other concerns induced by not complying with the recommended operating conditions of YANMAR engines with bio-diesel fuel.

Handling Fuel

WARNING! Diesel fuel is flammable and explosive under certain

conditions.

• NEVER refuel with the engine running.

• Always refuel outdoors or in a well ventilated area.

• Fill the fuel tank with diesel fuel ONLY. Filling the fuel tank with gasoline may result in a fire and will damage the engine.

• Remove flammable material containers from the box before filling them with fuel.

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

• Wipe up all spills immediately.

• Keep sparks, open flames or any other form of ignition (match, cigarette, static electricity source) well away when refueling.

• NEVER remove the fuel cap while the engine is running.

• NEVER overfill the fuel tank. Do not fill the tank neck.

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

Fuel Recommendations

Refueling

The fuel tank filler cap is located on the outside left side of the vehicle near the operator seat. Remove the cap and add the recommended fuel to the bottom of the filler neck. Do not overfill.

Cold Weather Operation

Cold weather operation can result in fuel gelling if the incorrect fuel type is used. Use the following fuel blending guideline to prev ent this from occurring.

Fuel Blending Guideline

Temperature No. 2 No. 1

+15° F (9° C) 100% 0%

Down to -20° F (-29° C) 50% 50%

Below -20° F (-29° C) 0% 100%

Block Heater Use

If this vehicle will be operated when temperatures are in the +5° to -25° F. (-15° to -32° C) range, a block heater must be installed. Please see your dealer to purchase a block heater kit.

OPERATION

Bio-Diesel Blended Fuel

NOTICE: Never use bio-diesel blended fuel containing more than

5% bio-diesel in this vehicle. See page 37.

Bio-diesel blended fuel has unique qualities that should be considered before using it in this vehicle:

• Cold weather conditions can lead to plugged fuel system

components and hard starting.

• Bio-diesel blended fuel is an excellent medium for micro-

bial growth and contamination which can cause corrosion and plugging of fuel system components.

• Use of bio-diesel blended fuel may result in premature fail-

ure of fuel system components, such as plugged fuel filters and deteriorated fuel lines.

• Shorter maintenance intervals may be required, such as

cleaning the fuel system and replacing fuel filters and fuel lines.

• Using bio-diesel blended fuels containing more than five

percent (5%) bio-diesel can affect engine life and cause deterioration of hoses, tubes, injectors, injector pump and seals.

OPERATION

Cold Weather Operation

Bio-Diesel Blended Fuel

Use the following guidelines if bio-diesel blended fuel is used:

• Never use bio-diesel blended fuel containing more than 5% bio-diesel in this vehicle.

• Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting in the fuel tank.

• Ensure that the fuel tank cap is securely tightened.

• Clean up any spilled fuel immediately to prevent damage to painted surfaces.

• Drain all water from the fuel filter daily before operating the vehicle.

• Do not exceed the engine oil change interval. Extended intervals can result in engine damage.

• Before vehicle storage, drain the fuel tank, refill with 100% petroleum diesel fuel, add fuel stabilizer and run the engine for at least 30 minutes.

NOTICE: Bio-diesel blended fuel does not have long term stability

and should not be stored for more than three months.

Operating Conditions

NOTICE: Observe the following environmental operating conditions

to maintain engine performance and avoid premature engine wear.

• Avoid operating in the presence of chemical gases or fumes.

• Avoid operating in a corr osive atmosphe re such as s alt water spray.

• NEVER operate the engine in a floodplain unless proper precautions are taken to avoid being subject to a flood.

• NEVER expose the engine to the rain.

• The standard range of ambient temperatures for the normal operation of YANMAR engines is from +5° F (-15° C) to +104° F (+40° C).

• If the ambient temperature exceeds +104° F (+40° C), the engine may overheat and cause the engine oil to break down.

• If the ambient temperature is between +5° F (-15° C) and 25° F (-32° C), POLARIS recommends the use of a block heater. See page 39.

Starting the Engine

START

HELP

NOTICE: NEVER use an engine

Before operating this vehicle in cold weather, review the cold weather operation infor mat ion beginning on page 39.

Always wait for the glow pl ug indi cator light to turn off before cranking the engine.

Tip: Engine will not start unless: Gear selector is in Park or Neutral,

1. Always start the engine outdoors or in a well-ventilated

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

3. Apply the brakes.

4. Put the gear selector lever in the Park position.

5. Turn the ignition switch to the ON position and wait for

6. Turn the ignition switch past the ON position to START.

7. If the engine does not start withi n five second s, rele as e the

starting aid such as ether. Engine damage will result.

travel control pedal is in neutral and PTO (if equipped) is OFF.

area.

the glow plug indicator light to turn off before cranking the engine.

Engage the starter f or a maximum of fi ve seconds. Rel ease the key when the engine starts.

ignition switch and wai t five second s. Repeat steps 5 an d 6 until the engine starts.

OPERATION

8. Allow the engine to warm to operating temperature. (For

Models HD and HD with the engine speed control lever to aid in warm up unt il the engine idles smoothly.)

NOTICE: Operating the vehicle immediately after starting could

cause engine and hydraulic compo nent damage . Allow the engine to warm up for several minutes before operating the vehicle.

Stopping the Engine

For maximum engine life, allow the engine to idle, without load, for 5 minutes. This will allow the engine components that operate at high temperatures, such as the exhaust system, to cool slightly before the engine is shut down.

1. Press the brake pedal until the utility vehicle comes to a

complete stop.

2. For models HD and HD

arm and put the attachment flat on the ground.

3. Move the gear selector lever to Park.

4. For models HD and HD

control lev er to low idle. Disengage the PTO and make sure all rotating components are completely stopped.

5. Turn the engine off and remove the key to prevent unau-

thorized use.

WARNING! A rolling vehicle can cause serious injury. Always place the gear selector lever in PARK before stopping the engine.

PTO; Vary the engine RPM slightly

PTO only: Lower the attachment

PTO only: Move the engine speed

OPERATION

Braking

1. Release the travel control pedal completely.

2. Press the brake pedal evenly and firmly.

3. Practice starting and stopping (using the brakes) until you're familiar with the controls.

Tip: When the travel control pedal is released, the vehicle hydraulic

system will slow the vehicle to a stop. Use the brake pedal to assist the stopping distance.

Driving Procedure

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

5. For Model HD; Raise the attachment arm. See page 44.

6. Apply the service brakes and shift the transmission into gear.

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

8. Keeping both hands on the steering wheel, slowly release the brakes and depress the travel control pedal with your right foot to begin driving. (Press the toe of the travel control pedal for forward travel, press the heel of the travel control pedal for backward travel.)

9. Drive slowly. Practice maneuvering and using the travel control pedal and brakes on level surfaces.

Tip: Allow the utility vehicle to come to a stop before changing direc-

tions with the travel control pedal.

10. Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

1. Wear eye protection.

2. Perform the pre-ride inspection. See page 35.

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

Driving with a Passenger

1. Perform the pre-ride inspection. See page 35.

2. Make sure all passengers are at least 12 years of age and tall enough to comfortably and safely sit in a passenger seat with the seat belt secured, put both feet on the floor and grasp the hand hold.

3. Make sure all passengers are wearing eye protection.

4. Make sure all passengers secure their seat belt.

5. Do not carry more than two passengers in the BRUTUS utility vehicle. Do not carry more than one passenger in models HD and HD

6. Allow a passenger to ride only in a passenger seat.

7. Slow down. Always travel at a speed appropriate for your skills, your passengers’ skills, and operating conditions. Avoid unexpected or aggressive maneuvers that could cause discomfort or injury to a passenger.

8. Vehicle handling may change with a passenger and/or cargo on board. All ow more time and distance f or braking.

9. Always follow all operating guidelines as outlined on safety labels and in this manual.

PTO.

OPERATION

Hydraulic Controls (Models HD and HD

PTO)

Joystick Operation

Start the engine. See page 41. Allow the hydraulic system to warm to operating temperature.

Tip: The utility vehicle has both a joystick lockout switch (Item 1) and

a tilt lockout switch (Item 2). When operating PTO driven attachments, the tilt lockou t switch wil l automatica lly activ ate. Using th e attachment with the til t lo ck ed out w ill lim it the pos s ibi lity of tilting the attachment while the PTO shaft is turning and putting stress on the PTO dri veline u-joints.

Tip: Before engaging the PTO sys-

tem, tilt the attachment to the desired operating position. See your attachment Owner’s Manual for detailed informa-

tion.

To lockout joystick functions; press the fr ont of the attachment joystick lock switch (Item

1) to enable th e joystick (Item

3) lockout feature. All functions of the joystick will be locked out.

T o lockout the tilt function; press the front of the attachm ent tilt lock switch (Item 2) to lockout the j oystick (Item 3) tilt function.

Tip: The utility vehicle engine must be running for the hydraulic sys-

tem to be activated.

Attachment Arm Operation

Movement of the joystick controls the hydraulic cylinders for the lift and tilt functions.

Pull the joystick backward to raise the attachment arm (Item 4).

Push the joystick forward to lower the attachment arm (Item 5).

Attachment Arm Float Position

Move the joystick fully forward (Item 6) until the joystick locks in the float position.

Use the float position of the attachment arm to level loose material ONLY while driving backward.

Pull the joystick backward (Item 4) to raise the attachment arm and release from the float position.

Tilt Operation

Move the joystick to the right to tilt the bucket forward (Item 7).

Move the joystick left to tilt the buc ket backward (Item 8).

Hydraulic Controls (Models HD and

2 3

PTO)

Front Auxiliary Hydraulic Operation

WARNING!

Avoid Injury Or Death. Diesel fuel or hydraulic fluid under

pressure can penetrate skin or eyes, causing serious injury or death. Fluid leaks under pressure may not be visible. Use a piece of cardboard or wood to find lea ks. Do not use your bare hand. Wear safety goggles. If fluid enters skin or eyes, get immediate medical attention from a physician fam iliar with this injury.

Tip: The utility vehicle engine must be running for the auxiliary

hydraulic system to be activated.

OPERATION

Press the left side of the auxiliary hydraulic switch (Item 2) to pressurize the female coupler.

Press the right side of the auxiliary hydraulic switch (Item 3) to pressurize the male coupler.

Move the switch to the le ft or to the right to control the front auxiliary hydraulics to operate an attachment. (EXAMPLE: T o rotate the snow blade to the left or right.) See your attachment Owner’s Manual for detailed information.

OPERATION

Hydraulic Controls (Models HD and HD

PTO)

Quick Couplers

WARNING!

Avoid Injury Or Death. Diesel fuel or hydraulic fluid under pressure can penetrate skin or

eyes, causing seriou s injury or dea th. Fluid lea ks under pressu re may not be visible. Use a pi ece of cardboard or wood to fin d le aks . Do n ot use your bare hand. Wear s afe ty go ggles. If fluid enters skin or eye s, get immediate medical attention from a physician familiar with this injury.

To Connect: Remove dirt or debris from the surface of both the male and female couplers, and from the outside diameter of the male coupler. Visually check the couplers (Item 1 and

2) for corroding, cracking, damage, or excessive wear. If any of these conditions exist, the coupler(s) must be replaced.

Install the male co upl er in to the female coupler. Full connection is made when the ball release sleeve slides forward on the female coupler.

To Disconnect: Relieve hydraulic p re ssure. Hold the male cou pler . Retract th e sleeve on the femal e coupler unti l the couple rs disconnect.

Relieve Hydraulic Pressure (Utility Vehicle And Attachment)

Utility Vehicle

• Lower the attachment arm fully and put the attachment flat on the ground. Stop the engine. Place the gear selector lever in Park. (The utility vehicle key needs to be in the ON position.)

• Move the switch (Item

1) to the left and right several times to relieve pressure at the couplers.

Attachment

• Follow procedure above to release pressure in the utilit y vehicle.

• Connect male coupler from attachment to femal e coup ler of the utility vehicle then repeat procedure above. This will release pressure in the attachment.

• Connect the female coupler from the attachment to the mal e coupler of the utility vehicle.

Hydraulic pressure in the auxi liar y hydrau lic sy st em can make it difficult to engage quick couplers to an attachment.

Power Take-Off (PTO) (Model HDPTO)

Description

The front PTO is standard equipment on the HD only.

The PTO must be in the disengaged (OFF) position before the engine can be started.

The PTO has a rated speed of 2000 RPM.

WARNING!

Avoid Injury Or Death

• Do Not exceed the rated attachment PTO speed.

• Stay clear of rotating driveline

• Keep bystanders away.

• Keep hands, feet, clothing and long hair away.

• Keep PTO shields and guards in place.

• Disengage PTO, put gear selector in PARK, stop the engine and make sure all rotating components are stopped before exiting utility vehicle.

• Do Not servic e the utility vehicle or attachment with the PTO engaged.

• Do Not service the attachment in a raised position unless properly

• Disengage PTO for road travel.

blocked and all rotating components stopped.

Engaging PTO

Tip: Do not engage the PTO system at higher engine rpm with the

attachment under load. Always engage the PTO system at a lower engine rpm an d with the attachmen t u nde r a no l oa d c ond ition.

PTO model

OPERATION

The operator must be in the operator seat to engage the PTO system. (If the o perator exits the machine with the PTO engaged, the PTO will shut off.)

Reduce the engine speed. On the PTO switch, press the

center button (Item 1) and then pull up on the knob (Item 2) to engage the PTO.

The light (Item 3) in the dash will illuminate and the PTO shaft will start rotating. The PTO RPM (Item 4) will be displayed.

Increase the engine speed to t he desired rpm spe cified for your attachment. See your attachment Owner’s Manual for the correct PTO rpm.

Disengaging PTO

Reduce th e engine speed to low idle. Press down on the PTO switch (Item 2) to the disengaged

(OFF) position. The light (Item 1) in the dash will tur n OFF and the PTO shaft will stop rotating.

WARNING!

Avoid Injury Or Death

• Keep PTO shield and all guards in place.

• Keep away from moving parts.

• Keep bystanders away.

• Do NOT exceed 2000 PTO RPM

OPERATION

Decal

Attachments (Models HD and HDPTO)

Choosing The Correct Attachment

WARNING! Avoid Injury or De ath. Never u se att ac hment s o r buck ets

which are not approved by Polaris. Buckets and attachments for safe loads of specific densities are approved for each mode l. U nap prov ed attachments can cause injury or death.

Tip: Any damage caused by the use of non-approved attachments is

not covered by warranty.

The dealer can identify, for the utility vehicle, the attachments and buckets approved by Polar is. The bucket s and atta chments are approved for attachment arm rated capacity and for secure fastening to the PRO-TACH.

The attachment arm rated capacity is determined by using a standard bucket and mater ia l of nor mal density, such as dirt or dry gravel. If very dense materi al is loaded, the volume must be reduced to prevent overloading.

• Longer stopping distance

• Faster tire wear

• Loss of stability

• Reduced utility vehicle life Use the correct si ze buc ket for the t ype and densit y of mat erial

being handled. For safe handling of materials and avoiding vehicle damage, the attachment (or bucket) should handle a full load withou t goi ng over the attachment arm rated capacity for the utili ty vehicle.

Choosing The Correct Attachment

Exceeding the arm rated capacity can cause the following problems:

• Difficult Steering

If a pallet fork attachment is use d, the load center moves forward and reduces the load capacity.

The maximum load to be carried when using a pallet fork is shown on a decal located on the pallet fork frame.

See your dealer for more information about pallet fork inspection, maintenance and replacement. See your dealer for attachment arm rated capaci ty when using a pallet for k a nd f or ot her available attachments.

Attachments (Models HD and HDPTO)

Installing And Removing Attachments

The PRO-TACH attachment system is used for fast changing of buckets and other attachments. See the appropriate Attachment Owner’s Manual to install other attachments.

Installing:

1. Remove the two retainers (I tem 1) and pins (Item 2) from the storage position.

2. Start the engine. See page 41. Move the gear selector lever to LOW.

3. Lower the attachment arm ant tilt the attachment interface forward.

4. Slowly drive forward until the front edge of the attachment interface is compl etely under the top l ip of the attachment (Ite m 3).

5. Tilt the attachment interface backward until the attachment is slightly off the ground.

6. Move the gear selector lever to PARK and stop the engine. See page 41.

OPERATION

7. Install the two pins (Item 1) and retainers (Item 2) (both sides).

8. Connect the auxiliary hydraulic hoses (if equipped). See page

46.

9. Connect the PTO driveline (if equipped). See page 51.

OPERATION

Attachments (Models HD and HDPTO)

Installing And Removing Attachments

Removing:

Tip: In muddy conditions or to prevent the a ttachmen t from freezing to

the ground, put the attachment on planks or blocks before removing the attach ment from the vehicle.

1. Lower the attachment arm and put the attachment flat on the ground

2. Move the gear selector leve r to PARK and stop the engine. See page 41.

3. If the attachment is hydraulically controlled, (snowblade, etc.), relieve the hydraulic pressure at the quick couplers. See page 46.

4. Disconnect the auxiliary hydraulic quick couplers. (if equipped). See page 46.

5. Disconnect the PTO driveline (if equipped). See page 51.

6. Remove the two retainers (I tem 1) and pins (Item 2) (both side).

7. Install the two pins (Item 3) and retainers (Item 4) into the storage position.

8. Start the engine. See page 41. Move the gear selector lever to LOW.

9. Be sure the attachment is fully lowered and the attachment is flat on the ground.

10. Tilt the attachment interface forward. Move backward, away from the attachment.

WARNING! Avoid Injury Or Death. Before you leave the operators seat:

• Park on flat level ground.

• Lower the attachment arm,

put the attachment flat on the ground.

• Press the brake pedal and move the gear selector lever to PARK.

• Disengage the PTO (if equipped) and make sure all rota ting com-

ponents are completely stopped.

• Stop the engine and remove the key.

Power Take-Off (PTO) (Models HDPTO)

Installing And Removing The PTO

The BRUTUS Model HD The PTO has a rated speed of 2000 RPM.

WARNING!

Avoid Injury or Death

• Do Not exceed the rated attachment PTO speed.

• Stay clear of rotating driveline.

• Keep bystanders away.

• Keep hands, feet, clothing and long hair away.

• Keep PTO shields and guards in place.

• Disengage PTO, put gear selector in PARK, stop the engine and make sure all rot ating component s are stoppe d before exi ting utility vehicle.

• Do Not service the utility vehicle or attachment with the PTO engaged.

• Do Not service the attachment in a raised position unless properly blocked and all rotating components stopped.

• Disengage PTO for road travel.

Installing

Install the attachment to the utility vehicle. See page 48. Stop the engine and exit the vehicle. See page 41. Make sure the PTO dri veline and all rotat ing component s have

come to a complete stop before exiting the vehicle.

NOTICE: Avoid PTO Driveline Damage

• Do not modify the attachment arm or PTO driveline.

• Make sure PTO driveline is the correct lengt h and that the ujoints are in the correct phase.

• Use only approved PTO drivelines desi gnated fo r the a ttach ment and never use unapproved attachments.

PTO is factory equipped with a PTO.

OPERATION

WARNING!

Rotating Parts Can Cause Serious Injury Or Death

• Disengage the PTO, put the gear selector in PARk, stop the engine and make sure all rotating components are completely stopped before connecting, disconnecting, adjusting or cleaning any PTO driven equipment.

• Always keep PTO shields and all guards in place when using the PTO driven equipment.

• Disengage PTO for road travel.

• Keep hands, feet, clothing and long hair away.

WARNING!

Driveline Entanglement Or Overspeeding PTO Can Cause Serious Injury Or Death

• Do Not install an adapter between the utility vehic le PTO shaf t and the attachment PTO driveline.

• An adapter can extend the driveline universal joint and connecting yoke beyond the PTO shields.

• An adapter can overspeed the attachment PTO causing driveline or attachment damage.

OPERATION

Power take-Off (PTO) (Models HDPTO)

Installing And Removing The PTO

Installing (Con’d)

Each attachment has a specific length PTO drive shaft that is affixed to the attachment. Do not intermix or replace drive sha ft s or components between different attachment types.

Connect th e PTO driveline (Item 1 ) to the PTO shaft of the utility vehicle. Make sure it is securely connected by pushing and pulling on the driveline. See your attachment Owner’s Manual for additional information.

Tip: The PTO driveline must have a means to retain it to the PTO

shaft on both the utility vehicle and the attachment.

WARNING! Avoid Injury or Death

• Keep PTO shields and guards in place.

• Keep away from moving parts.

• Keep bystanders away.

• Do Not exceed 2 000 PTO RPM

Removing

Stop the engine and exit the utility vehicle. See page 41.

Make sure the PTO driveline and all rotating components have come to a complete stop before exiting the utility vehicle.

Disconnect the PTO driveline (Item 1) from the utility vehicle. See your attachment Owner’s Manual for additional information.

WARNING! Rotating Parts Can Cause Serious Injury Or Death

• Always keep PTO shields and all guards in place when using the PTO driven equipment.

• Disengage PTO for road travel.

• Keep hands, feet, clothing and long hair away.

Driving Uphill

15° maximum

BRUTUS

15° maximum

HD and HDPTO

Whenever traveling uphill, follo w these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15°

maximum). For model HD and HD the heavy end of the vehicle uphill.

3. Keep both feet on the

floor.

4. Always check the ter-

rain carefully before ascending any hill.

5. Never climb hills with

excessively slippery or loose surfaces.

6. Proceed at a steady

rate of speed. Never move the travel control pedal or change direction of travel suddenly.

7. Never go over the cres t of a hill at high speed. An obstacl e,

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

PTO: Keep

OPERATION

Stalling While Climbing A Hill

Stalling or rol ling backwar ds while cl imbing a hil l could caus e overturn. Always maintain a steady speed whe n cl imbi ng hills.

If All Forward Speed Is Lost:

1. Apply the brakes.

2. Place the transmission in neutral and slowly allow the vehicle to roll stra ight do wnhill whil e applying light bra ke pressure to control speed.

If you Begin Rolling Downhill:

1. Never apply engine power.

2. Decelerate using the travel control pedal and apply the brake gradually until the vehicle is fully stopped.

3. Place the transmission in neutral and slowly allow the vehicle to roll stra ight do wnhill whil e applying light bra ke pressure to control speed.

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is no t recommended. I mproper proc edure could cause los s of con trol or overtur n. Avoid crossing the side of any hill unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill (15° maximum).

OPERATION

15° maximum

BRUTUS

HD and HD

PTO

15° maximum

Driving Downhill

When driving downhill, follow these precautions:

1. Avoid steep hills (15° maximum).

2. Drive straight

downhill. Avoid descending a hill at an angle, which would cause the vehicle to lean sharply to one side. Travel straight downhill when possible. For model HD and HDPTO: Keep the heavy end of the vehicle uphill.

3. Slow down.

4. Apply the brakes

slightly to aid in slowing.

OPERATION

WARNING

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly). When operating on slippery surfaces suc h as ic e or loose gravel, reduce speed and use extra caution to reduce the chance of skidding or sliding out of control. Do not operate on excessively slippery surfaces.

Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:

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

2. Slow down 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

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

spinning before engaging AWD.

OPERATION

BRUTUS

HD and HD

PTO

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 sl owly

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

Tip: For model HDPTO: When driving over objects (example: a curb),

always drive at a slight angle and at slow speed to allow one wheel at a time to go over the object. This will allow maximum ground clearance fo r the util ity ve hic le and avo id PT O s ha ft dam age.

Driving in Reverse

Follow these precautions when operating i n reverse:

1. Always check for obstacles or people behind the vehicle. Always inspect left and right fields of vision before backing. Always look in the direction of travel.

2. Always avoid backing downhill.

3. Back slowly.

4. Decelerate using the travel control pedal and apply the

brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never move the travel control pedal suddenly.

Driving Through Water

Floorboard

Your POLARIS BRUTUS can operate through water up to a maximum recommended depth equal to the floorboards.

NOTICE: Driving through water deeper than the floorboards will

NOTICE: Immersion can result in major damage if the vehicle isn't

Tip: For model HD and HD

Follow these procedures when operating through water:

1. Determine

cause engine damage and will also void the engine warranty.

serviced correctly and promptly. After immersion, always take the vehicle to a your dealer for service. Do not start the engine! If it's impossible to bring the vehicle to your dealer before starting the engine, perform the service outlined on page 93, and take the v eh ic le t o y our dea ler at the first opportunity.

PTO; It is not recommended to drive

through water with an attachment installed.

water depths and current before entering water.

OPERATION

2. Choose a crossing where b oth banks have gra dual in cline s.

3. Proceed slowly, avoiding rocks and obstacles.

4. Avoid operating through deep or fast-flowing water.

WARNING! The large tires on your BRUTUS may cause the vehicle to float in deep or fast-flowing water, which could result in loss of control and lead to serious injury or death. Never cross deep or fastflowing water with your BRUTUS.

5. After leaving water, always dry the brakes by applying light pressure to the pedal repeatedly until braking action is normal.

NOTICE: After operating the vehicle in water, it's critical that you

perform the services outlined in the Periodic Maintenance Chart beginning on page 77. Give special attention to engine oil, transmission oil, all gearcase fluids and all grease fittings.

OPERATION

15° maximum

Parking the Vehicle

1. Press the brake pedal until the utility vehicle comes to a complete stop. Stop the vehicle on a level surface.

2. 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.

3. For models HD and HD

arm and put the attachment flat on the ground.

4. Move the gear selector lever to Park.

5. For models HD and HD

control lever to low idle. Disengage the PTO and make sure all rotating components are completely stopped.

6. Turn the engine off and remove the key to prevent unau-

thorized use.

PTO only: Lower the attachment

PTO only: Move the engine speed

Parking on an Incline

Avoid parking on an incline if possible. If it's unavoidable, follow these precautions:

1. Apply the brakes.

2. Place the

transmission in PARK.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

OPERATION

WARNING

Hauling Cargo

Hauling cargo impro perly can al ter vehi cle ha ndlin g and m ay ca use lo ss of c ontrol or brake inst abil ity, which can result in serio us inj ury or d eath. Always fol low these precautions when hauling cargo:

Never exceed the vehicle rated capacity or the total rated capacity. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, attachments (models HD and HD The combined weight of these items must not exceed the vehicle rated capacity.

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO. 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. HEA VY LOAD S CAN CAUSE BRAKIN G AND CO NTROL PR OBLEMS. Use extreme c autio n when a pplyi ng bra kes with a loade d veh icle. A void

terrain or situations that may require backing downhill. USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected,

causing the vehicle to overturn. WARNING! 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 ) wh en to wing loa ds in rou gh te rrain , w hil e c orne ring , or w hi le ascending or descending a hill.

Driving with passengers in the cargo box can result in severe injury or death. Never allow passengers to ride in the cargo box. Passengers must always ride in the cab with seat belts fastened securely.

PTO Only), loads in the box and the load on the trailer tongue.

OPERATION

Hauling Cargo

The BRUTUS has been designed to carry or tow specific capacities. Always read and understand the load distribution warnings listed on the warning labels. The total load (operator, passenger, attachments, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle. Never exceed the following capacities.

Model Attachment Arm

BRUTUS Not Applicable 500 lbs. (225 kg) 1250 lbs. (567 kg) 150 lbs. (68 kg) 1750 lbs. (794 kg)

BRUTUS HD 500 lbs. (225 kg) 500 lbs. (225 kg) 1250 lbs. (567 kg) 150 lbs. (68 kg) 2000 lbs. (907 kg)

BRUTUS HD

A - Attachment Arm Rated Capacity * = 500 lb (225 kg) Maximum B - W e ig ht of Oc c upant(s) = 500 lb (225 kg) Maxim um C - Maximum Cargo Box Load = 1250 lb (567 kg) D - Maximum Trailer Hitch Tongue Weight = 150 lb (68 kg) E - Tow Weight (Level Ground) = 2000 lb (907 kg) (includes weight of trailer)

Vehicl e Rated Capacity = A plus B plus C plus D = (BRUTUS and BRUTUS HDPTO) 1750 lb (794 kg) / (BRUTUS HD) 2000 lb (907 kg) Maximum * Attachment Arm Rated Ca pacity is determined by using the standard bucket and material of normal de nsity, such as dirt or dry gravel. If other attachments,

such as Pallet forks are used, the load is moved forward and the attachment arm capacity is reduced. If very dense materi al is loaded, the volume must be reduced.

PTO 500 lbs. (225 kg) 500 lbs. (225 kg) 1250 lbs. (567 kg) 150 lbs. (68 kg) 1750 lbs. (794 kg)

Rate Capacity

Passenger

Compartment

Maximum Cargo Box

Weight Capacity

Maximum Trailer

Hitch To ngue W eigh t

Vehic le Rated

Capacity

OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of con tr ol or brake instabilit y. Always follow these precautions when towing:

1. Never load more than 150 lbs. (68 kg) tongue weight on the towing bracket.

2. Use low range. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 61. Towing a trailer increases braking dist anc e.

3. Do not tow more than the recommended weight for the vehicle. See the towing capacity chart on previous page and the specifications charts beginning on page 59.

4. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other location or you may lose control of the vehicle.

5. Never tow a trailer on a grade steeper than 15°.

OPERATION

Release Lever

Dumping the Cargo Box

1. Select a level site to dump the cargo box. Do not attempt to dump or unload the vehicle while parked on an incline.

2. Apply the brakes.

3. Place the transmission in

gear.

4. Engage the park brake.

5. Dismount the vehicle.

6. Ensure that the cargo is

positioned evenly or toward the front of the cargo box.

7. Release the tailgate by pulling up on the tailgate latch.

WARNING! If the weight distributi on on the box is loca ted tow a rd th e rear of the box when the release lever is pulled forward, the box may dump unexpectedly and cause serious injury to the operator or bystanders. Never operate the dump lever without ensuring that the load is positioned evenly or at the front of the box.

8. Stand clear and pull up on the cargo box release lever.

9. Lift the front of the cargo box to dump the cargo.

10. Lower the cargo box and push down securely to latch.

WARNING! Operating the vehicl e while the cargo b ox is raised c ould result in severe injury. The box could close unexpectedly and cause injury to the driver or pas seng er. The rear tires will also catch the rear of a raised box, d am agi ng the ve hic le and creating haza rdou s d r iv ing conditions. Never opera te this vehicle with the cargo box in the raised position.

Dumping The Cargo Box (With Power Lift Assist)

Press the top of the switch (Item 1) to raise the cargo box. Press the bottom of the switch (Item 1) to lower the cargo box.

Operating With A Full Bucket And Empty

Loaded Bucket And Empty Cargo Box

Going Up Slope Going Down Slope

Loaded Bucket And Empty Cargo Box

Going Up Slope

Going Down Slope

Cargo Box

OPERATION

Operating With An Empty Bucket And Loaded Cargo Box

With a loaded bucket and an empty cargo box, go up or down the slope with th e he avy end toward the top of the slope. Look in the direc tion of travel.

With an empty bucket and a loaded cargo box, go up or down the slope with the heavy end toward the top of the slope. Look in the direction of travel.

WARNING! Vehicle Tipping Or Rollover Can Cause Se riou s Inj ury or Death

• Keep the attachment arm as low as possible.

• Turn on level ground. Slow down when turning.

• Go up and down slopes, not across them.

• Keep the heavy end of the vehicle uphill.

• Do not exceed vehicle load capacity.

• Check for adequate traction.

Raise the bucket only high enough to avoid obstructions on rough ground.

Tip: When both ar empty or when both are loaded, the front and rear

of the vehicle are cl os e to the same weight. You can either move forward or backward up and down the slope.

OPERATION

Filling And Emptying The Bucket

Filling

Lower the attachment arm all the way (Item A) and tilt th e bucket forward (Item D) until the cutting edge is on the ground. Drive slowly forward to push the bucket slightly into the material.

Raise the attachment arm (Item B) and tilt the bucket backward (Item C).

WARNING!

Avoid serious Injury Or Death Load, unload and turn on flat level ground. Do not exceed vehicle

load capacity shown on sign (decal) in cargo box. Failure to obey warnings can cause vehicle rollover and can cause serious injury or death.

Drive backward away from the ma terial.

Emptying

Keep the bucket low when moving to t he area where you want to dump the material.

Move the machine slowly to the dump area.

While raising the attachment arm (Item B), tilt the bucket forward (Item D ) to keep it level and help prevent material from falling off the back of the bucket.

Tilt the bucket al l the way forward (Item D) to empty the bucket.

Leveling The Ground Using Float

Raise the attachment arm (Item B) and tilt the bucket forward (Item D).

Push the joystick all the way forward (Item AA) to activate float.

NOTICE: Never drive forward when the attachment arm is in the

Drive backw ard to level loose material. Pull the joystick backward (Item B) to unlock the attachment

arm from the float position.

float position.

OPERATION

Backfilling

Lower the attachment arm (I tem A) and put the cutting e dge of the bucket on the ground (Item D). Drive forward to the edge of the hole to push the material into the hole.

Tilt the bucket forward (Item D) as soon as it is past the edge of the hole.

If necessar y, raise the li ft arms to empty the bu cket.

OPERATION

All Wheel Drive (AWD)

Engaging AWD

Press the top of the rocker switch t o engage All Wheel Drive (AWD). The illuminated amber AWD switch indicates that the vehicle is in AWD.

When the AWD switch is on, the front wheels will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front wheels will automatically disengage . There is no limi t to the length of time the vehicle may remain in AWD.

Tip: The AWD switch may be turned on or off while the vehicle is

moving.

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

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

cause severe drive shaft and clutch damage. Always switch to AWD while the rear whee ls have tractio n or are at rest.

Disengaging AWD

Move the AWD switch to the center or bottom position to disengage AWD. If the switch is turned off while the front hubs are driving , they will not release until the rear wheels regain traction.

In some situations, the front gearcase may remain locked after turning the AWD switch off. If th is occurs, you may notice

increased steering effort and some vehicle speed restriction. Perform the following procedure to unlock the front gearcase.

1. Stop the veh i cle. Operate in rever se for at least 10 feet (3 m).

2. Stop compl etely. S hift into low gear and d rive forward.

3. If the front gearcase remains locked after followin g these

instructions, see your dealer for service.

Locking the Differential

NOTICE: Damage to the differe nti al

can occur if it is engaged while the vehicle is traveling at high spee ds or while the rear wheels are spinning. Slow the v ehicl e to nearly stopped before engaging the differential.

Locking the differential in slippery or low traction conditions helps improve traction. Move the rocker switch to the center position (2WD) t o lock the differential and operate in rear wheel drive.

Press the bottom of the switch to unlock the differential and allow the rear drive wheels to operate independently. This mode of operation is well suited to tur f driving or whenever aggressive traction is not required.

Safety Rules For PTO Operation (HDPTO)

WARNING!

Avoid Injury Or Death

• Do Not exceed the rated attachment PTO speed.

• Stay clear of rotating driveline.

• Keep bystanders away.

• Keep hands, feet, clothing and long hair away.

• Keep PTO shields and all guards in place.

• Disengage PTO, put transmission in Park, stop the engine and make sure all rot ating component s are stoppe d before exi ting utility vehicle.

• Do NOT service the utility vehicle or implement with the PTO engaged.

• Do NOT service the implement in a rais ed po si tion unless prope rly blocked and with all rotating components stopped.

• Disengage PTO for road travel.

WARNING!

Avoid Injury Or Death Before you leave the operator’s seat:

• Park on flat level ground.

• Lower the attachment arm, put the attachment flat on the ground.

• Press the brake pedal and move the gear selector lever to PARK.

• Disengage the PTO and make sure all rotating components are completely stopped.

• Stop the engine and remove the key.

WARNING!

Avoid Injury Or Death Warnings and instructions in this manual and on the machine are for

your protection. Failure to follow the warnings and instructions can cause serious

injury or death.

OPERATION

• Keep all shields in place. Replace damaged or missing shields before operating

• Follow warnings and instructions on machine signs (decals). Replace damaged or missing dec als .

• Do not wear loose or bulky clothing around the PTO or other moving parts.

• Keep bystanders away from PTO driven equipment, and never allow children near machines.

• Read and understand the manuals for the PTO driven equipment and be aware of safe operating procedures and hazards that may not be readily apparent.

• Always walk around equipment to avoid coming near a turning PTO driveline. Stepping over, leaning across or crawling under a turning PTO driveline can lead to entanglement.

• Do not install an adapter between the machine PTO shaft and the attachment PTO driveline.

• Never overspeed the PTO. See attachment Owner’s Manual for correct PTO speed.

• Position the machine and attachment correctly to prevent driveline stress and separation.

• Use caution when raising PTO driv en att a chment. Excessive d riv eline angle can reduce driveline service life.

• Do not engage the PTO system at higher engine rpm with attachment under load. Always engage the PTO system at a lower engine rpm and with attachment under a no load condition.

WARNING!

Driveline Entanglement Or Overspeeding PTO Can Cause Serious Injury Or Death

• DO NOT install an adapter between the utility vehicle PTO shaft and the attachment PTO driveline.

• An adapter can extend the driveline universal joint and connecting yoke beyond the PTO shields.

• An adapter can overspeed the attachment PTO causing driveline or attachment damage.

OPERATION

Operating The PTO (HDPTO)

The BRUTUS HDPTO utility vehicle is factory equipped with a PTO.

The PTO has a rated speed of 2000 RPM. Read and understand the attachment Owner’s Manual and the

utility vehicle Owner’s Manual prior to installing or using any attachment.

WARNING!

Avoid Injury Or Death

• Steering and braking can be affected by th e attachmen t, four wheel drive and the rear differential lock. Do not exceed the rated lift capacities.

• Always carry loads low. Slow down when turning.

Always inspect the utility vehicle and the attachment before use. Inspect for damaged or loose parts, damaged or missing PTO shields and guards.

New operato rs must operate the utility vehicle in an open area without bystanders. Operate the controls until the utility vehicle can be handled at a efficient and safe speed for all conditions of the work area.

Check for safe operating speed, safe stopping distances and braking characteristics that may be different with each type of attachment. Know that when attachments are inst alled, the utility vehicle braking distance increases.

Before beginning operation, inspect the work area for unsafe conditions.

Look for drop-offs or rough terrain. Have underground utility lines (gas, water, sewer, irrigation, etc.) located and marked.

Remove objects or other construction material that could damage the utility vehicle or cause personal injury.

Do not engage the PTO system at higher engine rpm with attachment under load. Always engage the PTO system at a lower engine rpm and with attachment under a no load condition.

WARNING!

Avoid Injury Or Death

• Do NOT exceed the rated attachment PTO speed.

• Stay clear of rotating driveline.

• Keep bystanders away.

• Keep hands, feet, clothing and long hair away.

• Keep PTO shields and all guards in place.

• Disengage PTO, put transmission in Park, stop the engine and make sure all rot ating component s are stoppe d before exitin g utility vehicle.

• Do NOT service the utility vehicle or implement with the PTO engaged.

• Do NOT service the implement in a raised position u nless properly blocked and with all rotating components stopped.

• Disengage PTO for road travel.

Operating The PTO (HDPTO)

See the attachment Owner’s Manual for the correct operating procedure for your attachment.

Install the attachment on the utility vehicle. See pages 49.

Engaging PTO:

1. Start the engine. See page 41.

2. Reduce the engine speed.

Tip: Do not engage the PTO

system at higher engine rpm with the attachment under load. Always engage the PTO system at a lower engine rpm and with the attachment under a no load condition.

3. On the PTO switch, press the center but ton (Item 1) and then pull up on the knob (Item

2) to engage the PTO.

4. The light (Item 3) in the dash will illuminate and the PT O shaft will start rotating. The PTO shaft RPM will be displayed in the dash (Item 4).

OPERATION

5. Increase the engine speed to the desired rpm specified for your attachment. See the attachment Owner’s Manual for the correct attachme nt oper ating RPM. (With engine RPM at 3600, the PTO shaft will rotate at approximately 2000 RPM. Adjust engine RPM to meet the attachment RPM requirement.)

Tip: The maximum PTO speed for various attachments may vary.

See the attachment Owner’s Manual for the maximum speed recommended for your attachment.

Tip: When driving over objects (example: a curb), always drive at a

slight angle and at slo w sp eed to allow one wheel at a time to go over the object. This will allow maximum ground clearance for the utility vehicle and avoid PTO shaft damage.

Tip: Do not engage the PTO system at higher engine rpm with the

attachment under load. Always engage the PTO system at a lower engine rpm an d wi th the attachment unde r a n o l oad c ond ition.

WARNING!

Avoid Injury Or Death

• Keep PTO shield and all guards

in place.

• Keep away from moving parts.

• Keep bystanders away.

• Do NOT exceed 2000 PTO RPM

ATTACHMENT ARM

Removing And Installing (Models HD and HD

PTO)

Description

When the PRO-TACH attachment system is not being used, it can be removed from the vehicle.

Tip: Remove the bucket or attachment before removing the attach-

ment arm from the vehicle.

Removing:

Tip: Before removing the attachmen t arm, it is rec ommended to ins tall

the Tilt Cylinder Stow Kit. The stow kit will secure the tilt cylinder in the storage position when the attachment arm is removed. See your Polaris dealer for parts.

1. Park the vehicle on a flat level su rface.

2. Lower the attachment arm fully and tilt the PRO-TACH fully forward.

Tip: In muddy conditions or to

prevent the attachment arm from freezing to the ground, put the attachment arm on planks or blocks before removing the attachment arm from the vehicle.

3. Move the gear selector leve r to PARK and stop the engine. See page 41.

WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm.

Tip: When the pin (Item 2) is

removed from the tilt cylinder , the interfac e will be free to tilt down to the ground. Support the interface while the pin is being removed.

4. Remove the retainer pin (Item 1) and the pin (Item 2) from the rod end of the tilt cylinder and position the interface flat on the ground.

5. Remove the retainer pin (Item 3) and pin (Item 4) from the rod end of the lift cylinder.

6. Start the engine. (See page 41. Press the bottom of the joystick lockout switch to enable the joystick.

7. Retract both the lift and tilt cylinders fully.

8. Press the top of the joystick lockout switch to disable the joystick.

9. Turn the key to the off position and exit the vehicle. See page 41.

Removing And Installing (Models HD and

PTO)

The PRO-TACH attachment system is used for fast changing of buckets and other attachments. See the appropriate attachment Owner’s Manual to install other attachments .

Removing (Cont’d):

Tip: The utility vehicle is

shown equipped with the optional cylinder Stow Kit (Item 1). See your Polaris dealer for parts.

Rotate the tilt cylinder up and into the storage position. Install the cylinder into the Stow Ki t (Item 1) (if equipped). If not equipped with the Stow Kit cylinder retainer, a heavy tie strap can be used to secure the cylinder to the grille in the storage position.

Position the cyli nder to th e frame and i nstall the pin (Item 3) and the retainer pin (Item 3) to secure the lift cylinder in the storage position.

ATTACHMENT ARM

Tip: When the pins (Item 5)

are removed from the attachment arm, it will be free to tilt down to the ground. Support the attachment arm w hile the pins are being removed.

Remove the two retainer pins (Item 4) and pins (Item 5) and lower the attachment arm fully.

Reinstall the pins (Item 5) and the retain er pins (Item

4) into the attachment arm for storage.

ATTACHMENT ARM

Removing And Installing (Models HD and HD

PTO)

Installing:

WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm.

1. Position the utility vehicle so it is centered in front of the attachment arm.

2. Remove the retainer pins and pins from the attachment arm (both sides).

3. Raise the attachment arm and position it to the vehicle mounting frame. Install the two pins (Item 1) and retainer pins (Item 2).

4. Remove the lift cylinder retainer pin (Item

3) and the pin (Item 4).

5. Remove the tilt cylinder from the Stow Kit (Item 5). Lower the tilt cylinder down and rest the rod end on the attachment arm.

Removing And Installing (Models HD and

PTO)

Installing (Cont’d):

6. Start the engine. See page 41. Press the bottom of the joystick lockout switch to enable the joystick.

WARNING! Avoid Injury. Keep fingers and hands out of pinch points when removing and installing the attachment arm.

7. Extend the lift cylinder full y.

8. Extend the tilt cylinder full y.

9. Press the top of the joystick lockout swi tch to lockout the joystick. Turn the key to the OFF position and exit the utility vehicle.

10. Raise the interface until it is aligned with the rod end of the lift cylinder . Install the pin (Item 1) and retainer pin (Item 2).

ATTACHMENT ARM

11. Rotate the interface upward until it is aligned with the rod end of the tilt cylin der. Install the pin (Ite m 3) and retainer pin (Item

4).

Lubricate the attachment arm and the cylinder grease fittings. See page

120.

PTO SYSTEM

Removing And Installing PT O Shafts (Models HD

Description

If the utility vehicle will not be used for PTO driven attachments for extended periods of time, it is possible to remove the PTO drive shaft assembly from the PTO clutch. This will prevent damage to the PTO system if the utility vehicle will be used off road or if additional ground clearance is desired.

Removing:

1. Stop the engine. See page 41.

2. Make sure the PTO driveline and all rotating components have come to a complete stop before exiting the utility vehicle.

3. Install the utility vehicle on jack stands. See page 111.

4. Remove the four bolts (Item 1) and remove the shield (Item 2).

Installation: Tighten the bolts to 7 - 8 ft-lb (9 - 10 Nm) torque.

PTO)

5. Remove the eight bolts (Item

3) and remove the belly pan (Item 4).

Installation: Tighten the bolts to 7 - 8 ft- lb (9 - 10 Nm) torque.

6. Remove the four bolts and nuts (Item 3) and remove the guard (Item 4).

Installation: Tighten the bolts to 32 - 35 ftlb (43 - 47 Nm) torque.

Removing And Installing PT O Shafts

(Models HDPTO)

Removing (Cont’d):

7. Remove the four bolts and nuts (Item 1) and remove the PTO shaft carrier assem bly (Item 2). (The carrier assembly will nee to be slide off the PTO shaft splines).

Installation: Tighten the bolts to 32 - 35 ft-lb (43 - 47 Nm) torque.

8. Remove the passengers seat to access the bolts for the rear of the PTO shaft. Remove the four bolts (Item 3 ) and remove the PTO shaft (Item

4) from the PTO clutch.

Installation: Tighten the bolts to 18 - 19 ft-lb (24 - 26 Nm) torque.

9. Reinstall the belly pan after the PTO shaft has been removed.

10. Place a ll the parts in a secure, dry area for installation at a later date.

11. Remove the machine from the jack stands. See page 111.

12. The utility vehicle will now have additional ground clearance foe off road use.

Installing:

1. Stop the engine and exit the vehicle. See page 41.

2. Make sure the PTO driveline and all rotating components have come to a complete stop before exiting the utility vehicle.

3. Install the utility vehicle on jack stands. See page 111.

4. Apply grease to the driveshaft splines.

5. Remove the belly pan.

6. Install all parts in reverse order.

PTO SYSTEM

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may af fect compli ance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise lev el requi rement s.

Operation on Public Lands in the U.S.A.

Y o ur POLARIS vehicle ha s a spark arrest er that was t ested and qualified to be in accor dance with th e 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- roa d veh ic les on publ i c la nds i n 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/.

Exhaust Emission Control System

Exhaust emissions are controlled by engine design. A fuel injection system controls fuel delivery. The engine and fuel injection c omponents are set at the factory for optima l performance and are not adjustable.

Your engine is designed to operate on low sulfur or ultra low sulfur diesel fuel onl y. Use of any other fuel may result in your engine no longer operating in compliance with emissions requirements.

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 t he applicable electromagnetic standards that apply to this vehicle.

Electromagnetic Interference

This vehicle complies with the EMC requirements of European directives 97/24/EC and 2004/108/EC.

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 av aila ble fr om your POLARIS dealer.

Record maintenance and service in the Maintenance Log beginning on page 136.

Tip: Service and adjustments are important for proper vehicle opera-

tion. If you're not fam ili ar w i th s afe se rvi ce and adj us tme nt p roc edures, have a qualified dealer perform these operations.

Maintenance intervals in the following chart are based upon average riding conditions and an average vehicle speed of approximately 10 MPH (16 km/h). Vehicles subjected to severe use must be inspected and servi ced more frequently.

MAINTENANCE

Severe Use Definiti on

• 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 Chart Key

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

E = Emission-related servi ce (Failur e to conduc t this main tenance will not void the emissions warranty but may affect emissions.)

D = Caution: Due to the nature of these adjustments, it is recommended this service be performed by an authorized POLARIS dealer.

Tip: Inspection may reveal the need for replacement parts. Always

use genuine Polaris parts.

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.

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval i s reached first.

Item Maintenance Interval

► Brake fluid level ► Coolant ► Diesel fuel level

►E Engine oil level

► Hydraulic oil level ► Brake system / pedal travel

Engine speed control lever (if applicable)

Travel control pedal Head lights/Tail lights Indicator lights/Switches

►E Air filter - Daily - Inspect filter element, replace as needed or every 150 hours ►E Air intake sediment drains - Daily - Inspect drains on bottom of engine air int ake duct and air filter housing for obstructions

► Cooling system - Daily - Inspect oil cooler, radiator A/C condenser (if equipped) and grills for debris, remove

Drive shaft boots Daily Inspect boots for damage, tears, ear or leaking grease

E Engine intake pre-filter screen (LH

side) Frame fasteners Daily Inspect and ensure tightness

► 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 Calen-

dar

- Daily - Check the levels and add as needed

Daily Ensure proper operation

- Daily - Check for proper operation

- Daily - Inspect; clean often

Miles

(Km)

debris if needed.

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

E Fuel filter/water separator - Daily - Drain daily (severe conditions with poor fuel quality) or every 50 hours

► Heater / A/C filter (if equipped) - Daily - Clean or replace filter as needed during heating and cooling seasons

PTO (if applicable) - Daily - Inspect; splines, guards, shields and mounting hardware. Tighten and

ROPS/OPS - Daily - Check the condition of the ROPS/OPS and mounting hardware Safety signs / Decals - Daily - Check for damaged signs (decals); replace any that are damaged Seat belts - Daily - Check the condition of the seat belts; clean or replace seat belt retrac-

Steering / suspension - Daily - Inspect for broken parts, loose hardware and free operation Tires - Daily - Check for wear, damage and correct tire pressure Wheels/fasteners - Daily - Check for loose wheel nuts and tighten to the correct torque value;

► Front gearcase lubricant (Demand Drive Plus) 25 H 1 M 250 (400) Initial fluid level inspection; add lubricant if needed ► Transmission lubricant (AGL Gearcase Lubri-

cant)

► Attachment interface mounting hardware (HD/

PTO

►D Brake pad wear - 1 M 250 (400) Initial fluid level inspection; add lubricant if needed

► 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

25 H 1 M 250 (400) Initial fluid level inspection; add lubricant if needed

25 H - - Re torque the lower mounting bolts to 95 ft-lbs

(Km)

(normal conditions with quality fuel)

replace as needed.

tors as needed

re-torque wheel nuts after 8 hours of use or any time the nuts are removed for service

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

D Alternator/Fan/Water pump drive belt 50 H - - Check and adjust the V-belt after the initial 50 hours of operation; per-

D Air conditioning drive belt (if applicable) 50 H - - Ch eck and adjust the V-belt after the initial 50 hours of operation; per-

►E Engine oil & filter change 50 H - - Perform an oil and filter change after the initial 50 hours of operation;

Hydraulic / hydrostatic system 50 H - - Replace hydraulic filter only after the initial 50 hours of operation;

Battery 50 H 1 M - Ch eck terminals; clean; test

E Fuel filter / water separator 50 H 3 M - Drain every 50 hours (normal conditions with quality fuel) or daily

► General grease lubrication 50 H 3 M 500 (800) Lubricate all grease fittings, pivots, etc.

E Air intake ducts / adapters 50 H 6 M - Inspect ducts for proper sealing/air leaks

Attachment interface mounting hardware

PTO)

(HD/HD PTO gearbox (if equipped) 100 H - - Inspect for leaks

►E Engine oil & filter change 100 H 6 M - Perform an oil and filter change after the initial 50 hours of operation;

► Front / rear suspension 100 H 6 M 1000 (1600) Inspect for wear

Shift cable / linkage 100 H 6 M 1000 (1600) Inspect, lubricate, adjust

D Steering 100 H 6 M 1000 (1600) Inspect steering freeplay

D,E Travel Control And Engine Speed Control

System

► 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

100 H - - Re-torque the lower mounting bolts to 95 ft-lbs

100 H 6 M 1000 (1600) Inspect for proper operation and adjust if necessary

(Km)

form every 200 hours thereafter

perform every 100 hours or 6 months thereafter

replace hydraulic fluid, filter and reservoir breather cap every 400 hours thereafter

(severe conditions with poor fuel quality)

perform every 100 hours or 6 months thereafter

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

Hours Calendar Miles

► Cooling Hoses 100 H 12 M - Inspect for leaks; replace if necessary ► Engine mounts 100 H 12 M - I nspec t, torque to specifications

Exhaust silencer/pipe 100 H 12 M - I nspec t

D,E Fuel system 100 H 12 M - Chec k for leaks at fill cap, fuel lines and fuel pump

D Front wheel bearings 100 H 12 M 1000 (1600) Inspect; replace as needed

► Front Gearcase lubricant (Demand Drive Plus) 100 H 12 M 1000 (1600) Change lubricant ► Transmission lubricant (AGL Gearcase Lubri-

cant) Hydraulic, hydrostatic and power steering hoses 100 H 12 M 1000 (1600) Inspect for damage and leaks; repair or replace as

► Radiator 100 H 12 M 1000 (1600) Inspect; clean external surfaces ► Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing, security; apply dielectric

Cooling system - 12 M - Test coolant strength and pressure test system

►E Air filter 150 H - - Replace air filter; replace more often if vehicle is subject

E Fuel filter/water separator 150 H 12 M - Replace fuel filter / water separator

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

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

100 H 12 M 1000 (1600) Change lubricant

(whichever comes first)

(Km)

needed

grease to connectors subjected to water, mud, etc.

to severe use

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Hours Calendar Miles

D Air conditioning drive belt (if equipped) 200 H - - Check and adjust the V-belt after the initial 50 hours of

D Alternator/Fan/Water pump drive belt 200 H - - Check and adjust the V-belt after the initial 50 hours of

D PTO drive belt (if equipped) 200 H - - Inspect for damage; replace as needed. D Toe adjustment 200 H 24 M 2000 (3200) Inspect; adjust if necessary or when parts are replaced D Brake fluid 200 H 24 M 2000 (3200) Change every two years (DOT 4)

Spark arrester, exhaust clean out 300 H 36 M - Rem ove plug and clean out Hydraulic / hydrostatic system 400 H - - Replace hydraulic fluid, filter and reservoir breather cap PTO gearbox lubricant (if equipped) 400 H 12 M - Change lubricant PTO shaft u-joints (if equipped) 400 H 12 M - I nspec t for wear; replace as needed PTO clutch brake (if equipped) 400 H 12 M - A djust tension

D,E Engine valve clearance 1000 H Inspec t and adjust as needed

► Coolant 1000 H 24 M - Replace coolant

D,E Fuel injectors 1500 H - - Inspect, clean and test fuel injectors, if necessary D,E Engine crankcase breather system 1500 H - - Inspect crankcase breather system

► Fuel hoses 2000 H 24 M - Replace rubberized fuel hoses ► Cooling hoses 2000 H 24 M - Replace coolant hoses

Headlight aim - Adjust as needed

► 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)

(Km)

operation; perform every 200 hours thereafter, replace as needed

operation; perform every 200 hours thereafter; replace as needed

Remarks

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 78, or more often under severe use, suc h as wet o r du sty cond itio ns. Ite ms not list ed in t he char t shoul d be lubr icat ed at t he gener al lu brication interval.

Item Lube Method

Engine Oil See page 87. Brake Fluid DOT 4 Maintain level between fill lines. See page 101. Main Gearcase Oil (Transmission) AGL PLUS Transmission Fluid S ee page 89. Front Gearcase Oil Demand Drive PLUS Fluid See page 90. Front Prop Shaft Yoke and PTO shaft P O LARI S Prem ium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120. Front and rear suspension POLARIS Prem ium U-Joint Lube Locate fittings and grease (3 pumps maximum). See page 120.

MAINTENANCE

Start Interlock System

Description

The utility vehicle is equipped with a Start Interlock System. The following must be in pla ce before the Utility Vehicle can be star ted:

• The gear selector lever must be in Park or Neutral or the travel control pedal must be in neutral.

• The PTO sw itch must be OFF.

Inspecting

To check the function of the Start Interloc k System, preform this pro cedure in an open area on flat level ground and make sure the area is clear of bystanders.

1. With the gear selector

lever (Item 1) in low gear and the PTO (Item 2) OFF, move the travel control pedal (Item 3) to the forward travel position, the engine must not start. Repeat the procedure with the gear selector in High and moving the travel control pedal into the reverse direction.

2. With the travel control pedal (Item 3) in neutral and the gear selector lever (Item 1) in PARK, move t he PTO (Item

2) to the ON position, the engine must not start.

If the engine star ts in any of the se positions , see your dealer fo r service.

PTO Interlock System (Model HDPTO)

Description

The utility vehicle is equipped with a PTO Interlock System. The following must be in place before the PTO can be engaged.

• The operator must be seated in the operators seat.

Inspecting

To check the funct ion of the PTO Interlock System;

1. With the operator in the operator seat, the gear selector lever in PARK, the engine running and the PTO engaged; Raise up on the operator’s seat (without exiting the utility vehicle) to take all weight of the operator’s seat. The PTO system must disengage. Monitor the dash panel to see that the PTO indicator turns OFF.

2. With the operator in the operator seat, the gear selector lever in PARK, the engine running, raise off of the operator’s seat, then activate the PTO system. The PTO must not engage.

If the PTO system does not function as described, stop using the utility vehicle and see your dealer for service.

Travel Direction And Engine Speed Control

WARNING

System (Models HD And HDPTO Only

Description

The travel direction control system on models HD and HD requires regular inspection. See information below.

Inspect the travel direction control and engine speed control system to ensure proper operation. Incorrect adjustment may cause erratic travel / engine speed conditions.

Avoid Serious Injury Or Death. Failure to check or maintain proper operation of the travel control

system can result in an accident and lead to serious injury or death if the travel control pedal or the engi ne speed cont rol lever st icks duri ng operation. Always inspect the travel control pedal for free movement and return to neutral before starting the engine and occasionally during operation. Never s tart or op erate thi s vehic le if it has a stic king or improperly o peratin g trav el c ontrol peda l. Im media tel y co nta ct y our dealer for service if travel control problems arise.

Inspection And Maintenance (For BRUTUS HD And HDPTO Models Only)

Position the utility vehicle on a flat level surface. Put the gear selector in PARK and stop the engine. Exit the utility vehicle.

Check the travel control pedal (Item 1) for excessive free play.

The correct amount of total free travel on the trave l control peda l

PTO

MAINTENANCE

is 7,6 mm (0.30 in). The engine speed control lever

(Item 2) will be used to control engine RPM. When on flat level ground, with the travel control pedal in neutral, move the gear selector lever to low and move the engine speed control lever to high idle. If any vehicle movement is detected, contact your dealer for service.

When on flat level ground, the gear selector lever in Park, press the travel control pedal to full forward, the engine speed should be 3650 - 3750 RPM. Repeat with travel control pedal fully in reverse, the engine speed should be 3650 - 3750 RPM

If the travel control pedal does not return to neutral unassisted during normal operation, see your dealer for service.

Use the engine speed contr ol lev er (It em 2) an d ch eck the high idle.

When on flat level ground, the gear selector lever in Park, move the engine speed control lever (Item 2) to high idle. The engine speed should be 3650 - 3750 RPM.

MAINTENANCE

WARNING

Horse Power Management

Description

Horsepower management auto matica lly incr eases or decrease s pressure to the hydrostatic transmission to sustain engine rpm and maintain optimum drive performance.

Avoid Serious Injury Or Death.

• Always keep bystanders away from the work area and travel path.

• The operator must always look in the direction of travel.

Inspection and Maintenance

Test conditions: Air Conditioning off, n o weight in cargo box, operator only. no attachment, no significant electrical loads:

In a controlled area, free of bystanders and on a flat level hard surface. Start the engine . See page

41. Operate the machine

until engine and hydraulics are at operating temperature. Move the gear selector lever to high. T r aveling i n a stra ight path , acceler ate at a high rate and monitor engine RPM. The engine RPM will increase moderately and then increase quickly to approximately 3200 - 3700 RPM and maintain this RPM. If engine speed does not meet this RPM range after 5 seconds of operation, contact your dealer for service.

If less responsive horsepower management is desired (i.e.: increased engine luggi ng during opera tion), see your dealer for adjustment.

Tip: Adjustments to the horsepower management systems are not

considered a defect and therefore are not a warrantable item.

Engine Oil

-25° F

(-31° C)

+5° F

(-15° C)

+80° F

(+27° C)

+104° F

(+40° C)

SAE 15W-40

Synthetic 5W-40

SAE 10W-30

Safe

{

Safe

Range

Check Level

on Top Side

Dipstick

Add

Always check the oil level daily. Change the engine oil at the intervals outl ined in th e Periodic Maintenance Chart begin ning on page 78. Always change the oil filter whenever changing oil.

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 Recommendations

NOTICE: Use of a non-recommended engine oil may cause serious

POLARIS recommends the use of POLARIS Diesel Oil (SAE CI-4) for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation. See the chart below.

Oil Viscosity/Ambient Air Temperature Chart

engine damage.

MAINTENANCE

Oil Check

The oil dipstick is located on the engine under the passenger seat.

Tip: Engine oil should be

checked cold or allo w time for the oil to drain back into pan before checking to prevent overfilling.

1. Position the vehicle on a level surface.

2. Stop the engine.

3. Tilt the rear ca rgo

box to access the engine oil dipstick.

4. Remove the dip-

stick. Wipe it dry with a clean cloth.

5. Reinstall the dip-

stick, then remove it and check the oil level. Maintain the oil level in the safe range. Do not overfill.

Tip: Due to the dipstick entry angle into the crankcase, the oil level

will read higher on the bottom side of the dipstick. Always read the level on the upper surface of the dipstick.

MAINTENANCE

Oil Fill Cap

Engine Oil

Oil and Filter Change

Always change the oi l and filter at the int ervals outlined in the Periodic Maintenance Chart beginning on page 78. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

2. Run the engine for two to three minutes until warm. Stop the engine.

3. Clean the area around the drain plug.

4. Place a drain pan beneath the engine crankcase.

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

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

6. Reinstall the sealing washer on the drain plug. 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 25 ft. lbs. (34 Nm).

8. Place shop towels beneath the oil filter. Using an 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.

10. Lubric ate the o-ring on the new filter with a film of fresh engine oil. Check to make sur e the o-ring is in good co ndition.

11. Install the new filt er and turn by han d until the filt er gasket contacts the sealing surface, then turn and additional 1/2 turn.

12. Remove the oil fill cap and add 2.75 quarts (2.6 l) of the recommended oil.

13. Reinstall the oil fill cap.

14. Shift the transmission to P ARK.

15. Apply the brakes.

16. Start the engine. Allow it to id le for one to two minutes.

17. Stop the engine. Inspect for leaks.

18. Allow time for the oil to drain back into the pan before checking to prevent overfilling the engine. Check the oil level on the dipstick and add oil as necessary to bring the level to the upper mark on the dipstick.

19. Dispose of used filter and oil properly.

Gearcases

Fill Plug

Fill Level

Drain Plug

Gearcase Specification Chart

BRUTUS Gearcase Specific ation s

Gearcase Lubricant Capacity Fill Plug

Main Gearcase

(Transmission)

Front

Gearcase

AGL PLUS

Transmission

Fluid

Demand Drive

PLUS Fluid

41 oz.

(1200 ml)

6.75 oz. (200 ml)

Torque

12 ft. lbs.

(16.3 Nm)

8-10 ft. lbs.

(11-13.6 Nm

Transmission (Main Gearcase)

Always check and change t he transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 78. Maintain the oil level even with the bottom of the fill plug hole threads.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and torque specifications. See page 128 for the part numbers of POLARIS products.

Drain Plug

Torque

12 ft. lbs.

(16.3 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

MAINTENANCE

Oil Check

The fill plug is located on the right side of the transmission. Access the fill plug from the rear right-hand side of the vehicle.

1. Position the vehicle on a level surface. Remove the fill plug.

2. Check the oil level. Add the recommended oil as needed.

3. Reinstall the fill plug. Torque to specification.

Oil Change

The drain plug is located on the bottom of the transmission. Access the drain plug from under the rear of the vehicle.

1. Remove the fill plug.

2. Place a drain pan under the

vehicle at the locat ion o f t he drain plug.

3. Remove the drain plug.

Allow the oil to drain completely.

4. Clean and reinstall the drain

plug with a new sealing washer. Torque to specification.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Dispose of used oil properly.

MAINTENANCE

Fill

Plug

Drain

Plug

Gearcases

Front Gearcase

Always check and ch ange the front ge arcase o il at the inte rvals outlined in the Peri odi c Mai ntenance Chart beginning on pa ge

78. Maintain the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 89 for recommended lubricants, capacities and torque specifications. See page 128 for the part numbers of POLARIS products.

Oil Check

The front gearcase fill plug is located on the right side of the front gearcase.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

Check the oil level.

3. Add the recom-

mended oil as needed.

4. Reinstall the fill plug. Torque to specification.

Oil Change

1. Support the vehicle securely on jack stands.

2. Remove the fill plug.

3. Place a drain pan under the drain plug on the bottom of the gearcase.

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

5. Clean and reinstall the drain plug. Torque to specification.

6. Add the recommended oil.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Dispose of used oil properly.

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery system components are the overflow bottle, radiator filler neck, radiator pressure cap and connecting hose.

As coolant operating temperature increases, the expanding (heated) ex cess coolant is forced out of the radiator, past the pressure cap, and into the overflow bottle. As engine coolant temperature decreases, the contracting (cooled) coolant is drawn back up from the tank, past the pressure cap, and into the radiato r.

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

Adding or Changing Coolant

To ensure tha t the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added.

NOTICE: Do not mix different types of coolant in the cooling system

when adding co olant. Mi xing type s can res ult in damage t o the cooling sy stem.

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

MAINTENANCE

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

Any time the cooling system h as been drained f or maint enance or repair , r eplace the cool ant. If the recovery bottle has ru n dry, the level in the radiator should be inspected. Add coolant as needed.

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outl ined in the Periodic M aintenance Chart beginn ing on page 78. Do not obstruct or deflect air flow through the radiator by installing unauthorized accessories in front of the radiator or behind the cooling fan. Interference with the radiator air flow can lead to overheating and consequent engine damage.

NOTICE: Washing the vehicle with a high-press ure hose could

damage the radiator fins and impair the radiator's effectiveness. Using a high-pressure system is not recommended.

MAINTENANCE

Maximum

Minimum

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals outlined in the Periodic Maintenance Chart beginning on page 78. Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool).

The overflow bottle is located under the hood.

1. Position the vehic le on a level surf ace.

2. View the coolant level

in the overflow bottle.

3. If the coo lant level is

below the safe operating range, lift the hood and locate the overflow bottle lid. Remove the cap and the rubber vented plug and use a funnel to add coolant through the f il le r open ing . Reins ta ll the rubber vented plug and the cap.

Tip: If coolant must be added ofte n, o r if th e o ver flow b ottl e ru ns com -

pletely dry, there may be a leak in the system. Have the cooling system inspected by your POLARIS dealer.

Radiator Coolant Level

1. Lift the hood.

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

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

4. Use a funnel and slowly add coolant as needed.

Tip: This procedure is required only if the cooling system has been

drained for maintenance and/or repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

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

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage

can result if the mac hin e i s n ot th orou gh ly ins pe cte d. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your BRUTUS to a dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the floorboards.

2. Drain water from the intake drain valve and thoroughly

dry the pre-filter box (l ocated at the left ROPS/OPS pos t) . See page 95.

3. Dry any water that is present in the air cleaner housing.

Filter replacement is required if water is present.

4. Remove the air intake resonator box and drain any water

that is present. Dry the box thoroughly.

NOTICE: If you believe water has entered the engine, Do Not start

the engine. Engine damage will result. Take the vehicle to your dealer before starting the engine.

5. Ta ke the vehicle to your dealer for service as soon as pos-

sible, whether you succeed in starting it or not.

6. Check the hydraulic fluid and differential fluid. If any

indication of moisture is present, replace the fluid and filters.

MAINTENANCE

Drain Valve Bleed Screw

Drain Hole

(viewed from bottom)

Tighten

Loosen

Fuel Filter/Water Separator

The fuel filter/water separator is located under the cargo box on the left side of the vehicle.

Inspect the separator daily for leaks. Drain water and replace the separator at the intervals outlined in the Periodic Maintenance Chart beginning on page 78. Service the separator more frequently if the vehicle is operated with poor qu ality fuel.

CAUTION! Both fuel and water will drain from the separator during the following procedure. Use caution and observe all fuel safety precautions when handling fuel.

1. Raise the cargo box.

2. Place an appropriat e containe r under the fu el filte r drain to catch fluids (water and fuel).

3. Slightly loosen the bleed screw to relieve fuel pressure in the filter. Do not tighten the screw at this time.

4. Reach under the fuel filter and slightly loosen the drain valve until the fluids drain from the drain hole. Do not completely unscrew the drain valve.

5. When fluids stop draining from the valve, tighten the valve firmly (by hand only). Tighten the bleed screw.

6. With the gear selector in Park, turn the key to the ON position. Do Not start the engine.

7. The fuel pump will start pumping fuel with the key in the ON position (10 -15 seconds) and will force air out of the fuel system.

8. At times it may be necessary to open the bleed screw on the fuel filter housing until fuel comes from the valve with no air bubbles.

9. Clean up any spilled fuel and soiled shop towels properly.

10. Start the engine and check for fuel leaks.

11. Lower the cargo box.

Air Pre-Filter

Pre-Filter

Latch

Pre-Filter Housing

Water Drain Valve

Always clean the pr e-filter at the intervals out lined in the Periodic Maintenance Chart beginning on page

78. Service the pre-filter more frequently if the vehicle is operated in wet or dusty conditions or at high engine RPM for extended periods.

The intake air pre-filter is located in the access pa nel on the left rear ROPS / OPS post. The pre-filter traps larger particles before the air reaches the main engine air filter.

Removal

1. Press the latch towards the front of the vehicle to remove the prefilter.

2. Clean debris from the

pre-filter and inspect for damage. If any damage is found, replace the pre-filter assembly.

MAINTENANCE

3. DO NOT use compressed air to clean the pre-filter open. Use a damp cloth and clean the inside of the pre-filter opening.

Installation

1. Insert the two tabs on the

pre-filter assembly into the side frame. Rotate the pre-filter into the frame and make sure the latch securely retains the pre-filter to it’s o riginal location.

Cleaning Intake Water Drain Valve

1. Raise the cargo box.

2. An air intake water drain valve is lo cated below the pre-filter that should be inspected and c lean a t the same tim e the pre-filter is cleaned.

3. Remove dirt and debris from the valve and squeeze the valve to make sure it is not plugged. If any damage is found, replace the drain valve.

MAINTENANCE

Clip

Cover

Filter

Clean Air Box

Air Filter

Always chan ge the air filter at the int ervals outlined in the Periodic Maintenance Chart beginning on page 78. Service the air filte r more frequently if the vehicle is operated in wet or dusty conditions or at high engine RPM for extended periods.

1. Lift the cargo box to access the air box.

2. Release the two air

box cover clips. Remove the air box cover.

3. Remove the air filter

assembly with a pulling and twisting motion. Use care to avoid damaging the filter element.

NOTICE: Operating a diesel engine with a soiled or damaged air

filter can result in engine damage. Do not attempt to wash the filter. Always replace a soiled or damaged filter with a new filter.

4. Clean any dirt or deposits from the air box.

5. Reinstall the filter into the air box. Make sure it fits tightly.

6. Install the cover and secure the with the two clips.

Hydraulic/Hydrostatic System

Sight Gauge Fill Cap

Checking Fluid

WARNING!

Avoid Injury Or Death. Always clean up spilled fuel or oil. Keep heat, flames, sparks or

lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.

Use only recommended fluid in the hydraulic system. Park the utility vehicle on

a flat level surface, lower the attachment arm and put the attachment flat on the ground. See page 44.

Move the gear selector lever to Park , stop the engine and exit the utility vehicle. See page 41.

Raise the cargo box. See page 62.

Check the fluid level in the sight gauge. The fluid level is correct when at the center of the sight gauge.

Use only recommended Polari s hydraul ic fluid when addi ng or changing the hydraulic fluid. See page 128.

MAINTENANCE

Adding Fluid

Clean the area around the fill cap. If needed, remove the fill/breather cap and add fluid. Lower the cargo box. See page 62.

MAINTENANCE

Fill/Breather Cap

Hydraulic/Hydrostatic Filter

Hydraulic/Hydrostat ic System

Removing And Replacing Hydraulic/Hydrostatic Filter

Change the hydraulic/ hydrostati c filter at t he intervals outlined in the Periodic Maintenance Chart beginning on page 78.

Park the utility vehicle on a flat level surface, lower the attachment arm and put the attachment flat on the ground.

Move the gear selector lever to Park , stop the engine and exit the utility vehicle. See page 41.

Raise the cargo box. See page 62.

Replace the fluid if it becomes contaminated or after major repair.

Thoroughly clean the area around the fill cap.

Loosen the fill / breather cap to relieve hydraulic system pressure.

WARNING!

Avoid Injury Or Death Diesel fuel or hydraulic fluid under pressure can penetrate skin or

Place a container under the filter. Recycle or d ispose of used oil in an environmentally safe manner.

Remove the hydraulic filter.

Clean the surface of the filter housing where the filter contacts the housing.

Put clean oil on the seal of the new filter. Install and hand tighten.

Tighten the fill / breather cap. Recycle or dispose of used fluid in an environmentally safe

manner.

WARNING!

Avoid Injury Or Death Always clean up spilled fuel or oil. Keep heat, flames, sparks or

lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.

Lower the cargo box. See page 62. Start the engine and operate the hydraulic controls. Stop the

engine and check for leaks. Check fluid level and add as needed. See page 97. Use only recommended fluid in the hydrauli c system. See page

128.

Hydraulic/Hydrostatic System

Fill Cap

Fill Screen

Removing And Replacing Hydraulic/Hydrostatic Fluid

Change the hydrauli c/hydrostat ic flui d at the i nterval s outline d in the Periodic Maintenance Chart beginning on page 78.

Replace the fluid if it becomes contaminated or after major repair.

Always replace the hydraulic / hydrostatic filters whenever the hydraulic fluid is replaced.

Move the gear selector lever to Park and stop the engine. See page 41.

Raise the cargo box.See page 62.

Remove the clamp (Item

1) and the hose (Item 2) from the gear pump fitting and drain the hydraulic fluid into a container.

Thoroughly clean the ar ea around the fill cap.

Slowly loos en the fill / breather ca p to relieve hydraulic system pressure in the tank. Remove the fill / breather cap.

MAINTENANCE

Remove and clean the hydraulic fill screen. Use low air pressure to clean the screen.

Remove the hydraulic filter. see page 98. Install a new filter.

Dispose of the used fluid in an environmentally safe manner.

Install the fill screen and fill to the proper level. See Page 99.

Install and tighten the fill / breather cap. Lower the cargo box. See page 62.

WARNING!

Avoid Injury Or Death Always clean up spilled fuel or oil. Keep heat, flames, sparks or

lighted tobacco away from fuel and oil. Failure to use care around combustibles can cause explosion or fire.

Start the engine and operate the hydraulic controls. If any hydraulic function operation is not smooth, this may indicate that air is trapped i n th e hyd raulic system. Continue to operate all the hydraulic functions until operation is smooth.

Stop the engine and check for leaks. Check fluid level and add as needed.

Polaris BRUTUS Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual