Polaris Defense MVRS 800 6X6 (2008) Owner's Manual

Polaris Defense Contact Information
Web: www.polarisdefense.com
E-mail: [e-mail]
Phone: [phone]
Part No. 9921652 Rev 01
Printed in USA

Pantone 4645CVC

WELCOME

Welcome to our world-wide family of Polaris owners and operators!
At Polaris Defense, we are committed to our many war fighters around

the world. Our family of light tactical all-terrain vehicles are combat
proven, providing mobility, sustainability, transportability and mission
flexibility to our dismounted war fighters.

We believe Polaris sets a standard of excellence for all utility and recre­ational vehicles manufactured in the world today. Many years of experi­ence have gone into the engineering, design, and development of your
Polaris vehicle, making it one of the finest machines we’ve ever pro­duced. For safe and enjoyable operation of your vehicle, be sure to fol­low the instructions and recommendations in this owner’s manual.

This manual contains instructions for minor maintenance. Major main­tenance and repairs are outlined in the Polaris Service Manual and
should be performed only by a factory-certified technician.

For sales, parts, technical information and support, please contact a
Polaris Defense representative.

Polaris Defense Contact Information

• Web: www.polarisdefense.com

• E-mail: [e-mail]

• Phone: [phone]
At Polaris, we are passionate about producing an exciting line of utility

and recreational products for our customers. We invite you to discover
your way out by becoming a proud owner of an award-winning
recreational vehicle from our huge family of Polaris vehicles.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility and recreational vehicles

• Victory motorcycles
You can find out more about Polaris by visiting our web site.

www.polarisindustries.com

1

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

Copyright 2007 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2008 Owner’s Manual P/N 9921652
MVRS 700 4X4/MVRS 700 6X6/MVRS 800 4X4/MVRS 800 6X6

2

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Features and Controls . . . . . . . . . . . . . . . . . . . 18

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 108

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 109

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 113

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

3

KNOW YOUR VEHICLE

As the operator of the vehicle, you are responsible for your personal
safety, the safety of others, and the protection of our environment. Read
and understand your owner's manual, which includes valuable informa­tion about all aspects of your vehicle, including safe operating proce­dures.

Refer to your service manual for vehicle specifications.

Vehicle Identification Numbers

Record your vehicle's identification numbers

VIN

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

in the spaces provided.

Engine Serial Number: ___________________________________________________

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements European directives

97/24/EC and 89/336/EEC.

4

SAFETY

Operator Safety

WARNING

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

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 and understand your owner's manual and all warnings before operating
the vehicle.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited
for anyone under 16 years of age. No person under the age of 5 may ride
as a passenger in this vehicle.

5

SAFETY

Operator Safety

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

The safety alert symbol, on your vehicle or in this manual, alerts you to the
potential for injury.

WARNING

The safety alert warning indicates a potential hazard that may result in serious
injury or death.

CAUTION

The safety alert caution indicates a potential hazard that may result in minor
injury or damage to the vehicle.

CAUTION

A caution indicates a situation that may result in damage to the vehicle.

NOTE

A note will alert you to important information or instructions.

6

SAFETY

Operator Safety

WARNING

Serious injury or death can result if you do not follow these instructions and
procedures, which are outlined in further detail within your owner's manual.

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

• Never allow anyone without a valid driver's license to operate this
vehicle.

• Minimum age recommendation for passengers is five years old. Pas­sengers under five years of age require special restraints which are
not available with this vehicle. Driver and passengers should wear
their seat belts at all times.

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

• To reduce tipover risk, be especially careful when encountering
obstacles and slopes and when braking on hills or during turns.

• This vehicle is for off road use only. Never operate on public roads.
Always avoid paved surfaces.

• Helmets are recommended whenever driving this vehicle in an
aggressive manner. Eye protection is recommended at all times.

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

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

• Never attempt jumps or other stunts.

• Always inspect your vehicle each time you use it to make sure it's in
safe operating condition. Always follow the inspection and mainte­nance procedures and schedules described in this manual.

• Always keep both hands on the steering wheel and both feet on the
floorboards of the vehicle during operation.

• 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.

7

SAFETY

Operator Safety

• Always follow proper procedures for turning as described in this
manual. 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 technician
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 hills.

• 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 loose surfaces.
Never open the throttle suddenly or make sudden gear changes. Never
go over the top of a hill at 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
attempt to operate over large obstacles such as rocks 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 vehicle in fast-flowing water or in water deeper
than that specified in this manual. Wet brakes may have reduced stop­ping ability. Test your brakes after leaving water. If necessary, apply
them lightly several times to let friction dry out the pads.

• Always be sure there are no obstacles or people behind your vehicle
when operating in reverse. When it's safe to proceed in reverse, move
slowly. Avoid turning at sharp angles in reverse.

• Always use the proper size and type of tires specified for this vehicle,
and always maintain proper tire pressure.

8

SAFETY

Operator Safety

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

• Never exceed the stated load capacity for this vehicle. Cargo should
be properly distributed and securely attached. Reduce speed and fol­low the instructions in this manual for hauling cargo or pulling a
trailer. Allow a greater distance for braking.

• Always wear the seat belts when operating this vehicle. Seat belts
reduce the severity of injury in case of a sudden stop or collision.

• Always keep arms and legs inside the cab frame while the vehicle is
in motion.

• Always engage the park brake before getting out of the vehicle. See
page 31.

• Always apply the service brakes before releasing the park brake.

• Always turn off the engine before refueling. Make sure the refueling
area is well ventilated and free of any source of flame or sparks.

9

SAFETY

Operator Safety

Equipment Modifications

WARNING

Make sure your vehicle is in excellent operating condition at all times. We
strongly recommend that the operator check all safety components before
each ride.

This vehicle is designed to provide safe operation when used as directed.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. The vehicle
may become unstable at speeds higher than those for which it is designed.
Loss of control may occur at higher speeds. Modifications may also create a
safety hazard and lead to bodily injury. Do not make any modifications to the
vehicle.

Polaris does not recommend that consumers install any equipment to the
vehicle that may increase the speed or power of the vehicle, or make any
other modifications to the vehicle for these purposes. Any modifications
to the original equipment of the vehicle create a substantial safety haz­ard and increase the risk of bodily injury.

The warranty on this vehicle 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.

NOTE: The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers, or large racks, may change the handling
characteristics of the vehicle. Use only Polaris-approved accessories,
and familiarize yourself with their function and effect on the vehicle.

10

Operator Safety

WARNING

POTENTIAL HAZARD
Stalling, rolling backwards while

climbing a hill
WHAT CAN HAPPEN
Vehicle overturn
HOW TO AVOID THE HAZARD
Maintain a steady speed when climbing

a hill.

If you lose all forward speed:

Apply the brakes.
Engage the park brake after fully stopped.

If you begin rolling backwards:

Never apply engine power.

SAFETY

Apply the brakes gradually.
When fully stopped, engage the park brake.
In the event of an accident, have a qualified service technician check the

complete vehicle for possible damage, including (but not limited to) brakes,
throttle and steering.

WARNING

POTENTIAL HAZARD
Operating this vehicle on paved surfaces
WHAT CAN HAPPEN
Loss of control
HOW TO AVOID THE HAZARD
This vehicle's tires are designed for off-road use only, not for use on

pavement. Paved surfaces may seriously affect handling and control of the
vehicle, and may cause the vehicle to go out of control.

Avoid operating the vehicle on pavement. If you must operate on a paved
surface, travel slowly and do not make sudden turns or stops.

11

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Operating this vehicle without proper instruction
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
The risk of an accident is greatly increased if the

operator does not know how to operate the
vehicle properly in different situations and on
different types of terrain.

All operators must read and understand the
Owner's Manual and all warning and instruction labels before operating the
vehicle.

WARNING

POTENTIAL HAZARD
Operating this vehicle on public streets, roads or highways
WHAT CAN HAPPEN
Collision with another vehicle
HOW TO AVOID THE HAZARD
Never operate this vehicle on any public street, road or highway, including

dirt or gravel.
In many states it's illegal to operate vehicles of this type on public streets,

roads and highways.

12

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Operating this vehicle after consuming alcohol

or drugs
WHAT CAN HAPPEN
Could seriously affect your judgment.
Could cause you to react more slowly.
Could affect your balance and perception.
Could result in an accident.
HOW TO AVOID THE HAZARD
Driving this vehicle requires your full attention. DO NOT drink alcohol or use

drugs or medications before or while driving. They will reduce your alertness
and slow your reaction time. In most states and provinces, it's prohibited by
law to drive while intoxicated or under the influence of drugs.

WARNING

POTENTIAL HAZARD
Operating this vehicle at excessive speeds
WHAT CAN HAPPEN
Loss of control, accident
HOW TO AVOID THE HAZARD
Always travel at a speed proper for the terrain, visibility and operating

conditions, and your experience.

WARNING

POTENTIAL HAZARD
Attempting jumps and other stunts
WHAT CAN HAPPEN
Loss of control, accident and/or vehicle overturn
HOW TO AVOID THE HAZARD
Never attempt jumps and other stunts. Avoid exhibition driving.

13

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Operating on frozen bodies of water.
WHAT CAN HAPPEN
Severe injury or death can result if the vehicle and/or the operator fall through

the ice.
HOW TO AVOID THE HAZARD
Never operate the vehicle on a frozen body of water.

WARNING

POTENTIAL HAZARD
Failure to inspect the vehicle before operating
Failure to properly maintain the vehicle
WHAT CAN HAPPEN
Accident, equipment damage
HOW TO AVOID THE HAZARD
Always inspect your vehicle before each use to make sure it's in safe

operating condition.
Always follow the inspection and maintenance procedures and schedules

described in the Owner's Manual.

WARNING

POTENTIAL HAZARD
Failure to use extra caution when operating this vehicle on unfamiliar terrain
WHAT CAN HAPPEN
Loss of control, vehicle overturn
HOW TO AVOID THE HAZARD
Travel slowly and use extra caution when operating on unfamiliar terrain.
Always be alert to changing terrain conditions when operating the vehicle.

You may come upon hidden rocks, bumps, or holes suddenly, without
enough time to react.

14

SAFETY

Operator Safety

WARNING

POTENTIAL HAZARD
Failure to follow the minimum age recommendations for this vehicle
WHAT CAN HAPPEN
Serious injury or death (the child or others)
HOW TO AVOID THE HAZARD
Only persons with a valid driver's license should operate this vehicle.
Even though a child may be within the age group for which some vehicles are

recommended, he or she may not have the skills, abilities, or judgment
needed to operate the vehicle safely and may be involved in a serious
accident.

WARNING

POTENTIAL HAZARD
Operating this vehicle with improper tires or with improper or uneven tire

pressure
WHAT CAN HAPPEN
Loss of control, accident and/or overturn
HOW TO AVOID THE HAZARD
Always use the size and type of tires specified for this vehicle.
Always maintain proper tire pressure as specified for this vehicle.

15

SAFETY

Operator Safety

WARNING

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

WARNING

Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause serious 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.

16

SAFETY

Fuel Safety

WARNING

Fuel is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling fuel.

Always stop the engine when refueling.
Always refuel outdoors or in a well ventilated area.
Do not smoke or allow open flames or sparks in or near the refueling area or

where fuel is stored.
Do not over fill the 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.
Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness and death in a short
time.

17

FEATURES AND CONTROLS

Component Locations

Cab

Frame

Dash Panel

Front

Platform

Seat

Steering

Wheel

Seat

Belts

Storage Box

(under seat)

Winch

Headlights

Front Bumper/Brush Guard

Battery

(behind panel)

Run-Flat

Tires

18

FEATURES AND CONTROLS

Component Locations

Tailgate

Latch

Release

Tailgate

Cargo

Box

Taillights

Air Box

Receiver

Hitch

CV Boot/Rear

Caliper

Muffler

(Spark Arrestor)

19

FEATURES AND CONTROLS

Trailer Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 52-55.

Run-Flat Tires

This vehicle is equipped with run-flat tires, which permit limited opera­tion with a flat tire. However, vehicle load capacity is reduced when tire
air pressure is lost. Remove cargo from the vehicle and do not tow a
load with flat tires. Vehicle characteristics, including braking and han­dling, may also be affected by operating with flat tires. If you must oper­ate the vehicle with a flat tire, drive no further and no faster than
necessary, and travel on smooth and level terrain whenever possible.

WARNING

Failure to reduce travel distance, vehicle speed and cargo weight when air
pressure is lost in run-flat tires could result in loss of control or tire damage.
This could lead to serious injury or death.

If you must operate the vehicle with flat tires, remove all cargo and towed
loads from the vehicle. Do not exceed 50 miles (80 km) at 25 MPH (40 km/h).

Have the tire(s) inspected by an authorized Polaris service technician as
soon as possible and before further use.

20

FEATURES AND CONTROLS

Rear Box/Flatbed Conversion

The rear box panels can be
lowered to create a flatbed.
Lower the tailgate panel first.

1. Remove the tailgate
retainer cables from the
box sides.

2. Release the tailgate
latches and allow the
tailgate to pivot down­ward.

3. Release the side latch at
the top front corner of
each side panel and
allow the panels to pivot downward.

Fuel Cap

The fuel tank filler cap is located
on the right-hand side of the vehi­cle near the passenger seat.

Latches

Fuel Requirements

MVRS 700

When refueling, always use either
leaded or unleaded gasoline with a
minimum pump octane number of
87 R+M/2 octane. Do not use E-85

fuel.

MVRS 800

Use only JP8 fuel for this vehicle.

Fuel Cap

21

FEATURES AND CONTROLS

Seat Belts

This Polaris vehicle is equipped with four-point harness-style seat belts
for the operator and passenger, and for accessory jump seat passengers.
Inspect seat belts for wear, cuts or damage before each use of the vehi­cle. Replace worn or damaged seat belts promptly. Always make sure
the seat belts are secured for the operator and passengers before riding.

1. Sit in the seat and place the
shoulder belts over your shoul­ders. Make sure the belts are
not twisted.

2. Slide each shoulder belt link

over the flat end of the lap belt.

3. Slide the flat end of the lap belt

through the latch loop of the
remaining lap belt and press
the hook latch down to secure
it. Make sure the hook loops
through the flat end section.

WARNING

Riding in this vehicle without wearing the seat belt can result in serious injury
or death in the event of an accident or sudden stop. Always make sure the
seat belts are secured for the operator and passengers before riding.

Seat Removal

To remove the seat, pull up on the front of the seat and slide it toward
the front of the vehicle.

Install the seat by sliding the tabs into the rear of the seat base. Push
down firmly on the front of the seat until the pins are fully seated into
the grommets.

22

FEATURES AND CONTROLS

Dash Panel Removal

Remove the front dash panel to access electrical components, power
receptacles, engine and clutch intake ducts and brake master cylinder.
Refer to the illustration below.

1. Remove the 10 screws securing the panel to the frame.

2. Remove the panel from the vehicle.

Front Platform Panel Removal

Remove the front platform panel to access the radiator, coolant bottle
and other components.

NOTE: Remove the front dash panel before removing the platform panel.

1. Remove the four screws securing the panel to the frame.

2. Remove the bolt at each upper corner of the front grille.

3. Remove the panel from the vehicle.

Dash Panel

10 Screws

Front Platform Panel

4 Screws

Bolts

23

FEATURES AND CONTROLS

Console

Instrument

Gauge

Mode

Button

Battery

Switch

Brake Fluid

Access

Panel

Steering

Lock

Park Brake

Lever

Ignition

Switch Lever

Gear

Selector

Switches

Winch

Remote

Receptacle

12-Volt

Accessory

Outlets

Passenger

Grab Handle

Electrical

Access Panel

Auxiliary Outlets

Each 12-volt accessory plug receptacle has a spade connection on the
back that may be used to power an auxiliary light or other optional
accessories or lights.

Mode Button

The yellow mode button is used to toggle through mode options avail­able such as odometer, trip meter, hour meter, tachometer and clock. See
page 34 for operating procedures.

24

FEATURES AND CONTROLS

Console

Slave Receptacles

This vehicle is equipped with a system designed to assist in either
recharging the battery or starting the engine of a vehicle that has a dis­charged battery.

NOTE: When connecting a power source to a slave receptacle, always con-

nect like polarities. Connect positive to positive. Connect negative to
negative.

12-Volt Jump-Start Capable System

The 12-volt jump-start capable system is directly wired parallel to the
vehicle’s battery and charging system. Connect an external 12-volt
power source to this receptacle to either recharge or jump-start the dis­abled system.

Steering Lock

Locking the steering can prevent theft or
unauthorized use of the vehicle. Install a
lock to the base of the steering shaft as
shown to lock the steering.

25

FEATURES AND CONTROLS

Console

Gear Selector

Gear Selector

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

NOTE: Low gear is the primary driving

range for this vehicle. High gear
is intended for use on hard­packed surfaces with light loads.

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

NOTE: Maintaining shift linkage adjustment is important to assure proper

transmission function. See your Polaris service technician if you expe­rience any shifting problems.

CAUTION

Do not attempt to shift the transmission while the vehicle is moving or
damage to the transmission could result. Always shift when the vehicle is
stationary and the engine is at idle.

26

FEATURES AND CONTROLS

Switches

Battery Switch

The main battery switch is located on the
dash at the left side of the steering wheel. If
electrical components do not operate, reset
the main battery switch.

OFF/TRIP: Shuts down all electrical power
to the vehicle

ON/RESET: Restores electrical power to the
vehicle

Ignition Switch Lever

Move the ignition switch lever clockwise
past the ON position to start the engine.
See page 42 for starting procedures.

OFF The engine is off. Electrical

circuits are off, except 12-volt
receptacle.

ON Electrical circuits are on. Electrical

equipment can be used.

START Move the ignition switch lever

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

Ignition Switch Lever

27

FEATURES AND CONTROLS

Switches

AWD

Switch

Headlight/Tail Light

Switch

IR Switch

Blackout Switch

To activate blackout mode (turn off all
lights), press the top of the blackout
rocker switch toward the dash.

Winch

Switch

Blackout

Switch

Activate

Blackout

To deactivate blackout mode and allow
operation of the headlights, press the
bottom of the rocker switch toward the
dash. The red bar lens will illuminate
when blackout mode is deactivated.

Infrared (IR) Drive Switch

To activate the IR lights, press the top of
the IR Drive rocker switch toward the
dash.
remain off.

To deactivate the IR lights and allow oper­ation of other lights, press the bottom of
the rocker switch toward the dash. If
blackout mode is not activated, the green
bar lens will illuminate when the IR lights
are deactivated.

All other lights on the vehicle will

Deactivate

Blackout

Activate

IR Lights

Deactivate

IR Lights

28

FEATURES AND CONTROLS

Switches

Winch Operation Switch

Use this switch to operate the winch. Winch
operation instructions can be found in the winch
operation guide provided by the winch manufac­turer.

Install the winch remote to the remote winch
receptacle to operate the winch switch remotely.
The remote is located in the tool pouch.

Headlight/Taillight Switch

The blackout and IR light modes must be

HIGH

deactivated, and the ignition switch must be
in the ON/RUN position to operate the head­lights and taillights. The taillights operate

LOW

when the light switch is set to either high
beam or low beam.

NOTE: If the lights fail to operate, check the

battery switch.

OFF

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
headlights on low beam. Press the bottom of the rocker switch to turn
off the headlights and taillights.

AWD/Differential Lock Switch

The AWD/Differential Switch has
three positions:

• All Wheel Drive (AWD)

• Differential Lock (2WD)

• Differential Unlock

All Wheel Drive

Differential Lock

Press the top of the rocker switch to
engage All Wheel Drive (AWD). See

57 for operating instructions.

page

Differential Unlock

Move the rocker switch to the center
position to lock the differential and operate in rear wheel drive. See page
58 for Differential Lock operating instructions.

Press the bottom of the switch to unlock the differential and allow the
two rear drive wheels to operate independently.

29

FEATURES AND CONTROLS

Brake Pedal

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

Throttle Pedal

Push the pedal down to increase
engine speed. Spring pressure
returns the pedal to the rest position
when released. Always check that
the throttle pedal returns normally
before starting the engine. Make
sure there's adequate throttle pedal
freeplay. See page 86
pedal adjustment procedures.

for throttle

Brake
Pedal

Throttle

Pedal

30

Park Brake Lever

FEATURES AND CONTROLS

Engage the park brake when parking
the vehicle to help prevent the vehi­cle from rolling. Always apply the

Park Brake

Lever

Park Brake

Release

service brakes before engaging or
releasing the park brake.

1. Apply the brakes.

2. Pull the park brake lever down­ward as far as possible.

3. To release the park brake, apply
the brakes. Press the park brake
release inward and move the
lever upward as far as possible.

WARNING

Operating the vehicle while the park brake is engaged could cause loss of
control and result in serious injury or death. Always disengage the park brake
before operating the vehicle.

When the park brake is fully engaged and the park brake indicator is
illuminated, engine speed is limited to 1300 RPM in all gears, including
neutral. If throttle is applied, this limiting feature prevents operation,
which protects the park brake pads from excessive wear.

Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension.
See page 88.

NOTE: This feature will not operate properly if the park brake connector or

switch (under the dash) malfunctions or becomes disconnected, or if
the switch has moved. Check for disconnection, then see your Polaris
service technician promptly if this feature fails to operate properly.

31

FEATURES AND CONTROLS

Component Locations

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. The instrument cluster measures dis­tance in miles as well as time, hours of operation and engine RPM.
Refer to page 24 for the location of the instrument cluster.

Park Brake

Indicator

Speedometer

Needle

Speedometer

Rider

Information

Center

NOTE: In addition to showing vehicle speed, the speedometer needle flashes

when a low fuel condition exists.

32

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All seg­ments will light up for 2.5 seconds at start-up.

NOTE: If the instrument cluster fails to illuminate, a battery over-voltage may

have occurred and the instrument cluster may have shut off to protect
the electronic speedometer. If this occurs, take the vehicle to your
Polaris service technician for proper diagnosis.

1. Gear Indicator - This
indicator displays gear

345

6

7

shifter position.
H = High Gear
L = Low Gear
N = Neutral
R = Reverse Gear

2. AWD Indicator - This

2

indicator illuminates
when the AWD switch
is in the AWD posi-

1

tion.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

8

6. Odometer/Tachometer/Tripmeter/ Hour Meter/Clock

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

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

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

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

33

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode button located under the speedometer to toggle
through the mode options. See page 24.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if
it's reset before each trip. To reset the trip meter, select the trip meter
mode. Press and hold the mode button (override button) until the total
changes to 0.

NOTE: In the Rider Information Center, the trip meter display contains a deci-

mal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

of changes in humidity, temperature and elevation.

Clock Mode

The clock displays time in a 12-hour format. To reset the clock, see page

35.

34

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the park brake.

3. Place the transmission in neutral.

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

on. Release the switch as soon as the display is activated.

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

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

3. Press and hold the mode button until the hour display flashes.

Release the button.

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

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

5. When the desired hour is displayed, wait approximately four sec-

onds, until the minute display flashes.

6. When the display stops flashing, the mode has been set.

7. Use the same procedure to reset the minutes.

35

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

The gauge indicates whether or not current is flowing through the AWD
coil (only on models with switchable AWD). This screen is for informa­tional purposes only. Please see a Polaris Defense service technician for
all major repairs.

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 37.

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

36

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about seven (7) seconds, until

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

NOTE: If you scroll past the intended number, press and hold the button until

the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

37

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see
a Polaris Defense service technician for all major repairs.

See page 39 for Blink Codes and Failure Descriptions. Use the follow­ing procedure to download blink codes (failure codes) from the EFI
module.

1. Apply the brakes. Stop the engine.

2. Engage the park brake.

3. Turn the ignition switch to the ON position.

4. Turn the ignition switch off and on three times in less than five sec­onds, then leave the switch on. Any blink code numbers stored in
the EFI module will display, one at a time, on the screen. The num­ber “61” and the word “END” displays after all codes have been
transmitted.

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Failure Description

Code

-- No RPM Signal
21 Loss of Synchronization
45 Barometric Pressure Sensor: Circuit Low Input
46 Barometric Pressure Sensor: Circuit High Input
22 TPS: Open or Short Circuit to Ground
22 TPS: Short Circuit to Battery
23 RAM Error: Defective ECU
42 Engine Temp Sensor Circuit: Short to Ground
42 Engine Temp Sensor Circuit: Open or Short to Battery
51 Injector 1: Open Load
51 Injector 1: Short Circuit to Ground
51 Injector 1: Short Circuit to Battery
52 Injector 2: Open Load
52 Injector 2: Short Circuit to Ground
52 Injector 2: Short Circuit to Battery
53 Rear Differential: Open Load
53 Rear Differential: Short Circuit to Ground
53 Rear Differential: Short Circuit to Battery
54 Engine Temp Lamp: Open Load
54 Engine Temp Lamp: Short Circuit to Ground
54 Engine Temp Lamp: Short Circuit to Battery
55 Diag Lamp: Open Load
55 Diag Lamp: Short Circuit to Ground
55 Diag Lamp: Short Circuit to Battery
56 Pump Relay: Open Load
56 Pump Relay: Short Circuit to Ground
56 Pump Relay: Short Circuit to Battery
57 Reverse Beeper: Open Load
57 Reverse Beeper: Short Circuit to Ground
57 Reverse Beeper: Short Circuit to Battery
58 Cooling Fan: Open Load
58 Cooling Fan: Short Circuit to Ground
58 Cooling Fan: Short Circuit to Battery
41 Intake Air Temp Sensor: Open or Short Circuit to +Sensor Voltage
41 Intake Air Temp Sensor: Short Circuit to Ground
61 END

39

OPERATION

Break-In Period

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

CAUTION

Excessive heat build-up during the first three hours of operation will damage
close-fitted engine parts. Do not operate at full throttle or high speeds for
extended periods during the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with fuel. Heed the fuel warnings on page 17.

2. Check the oil level. See page 66. Add the recommended oil as
needed to maintain the oil level in the normal (safe) operating
range.

3. Drive slowly at first. Select an open area that allows room to famil­iarize yourself with vehicle operation and handling.

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

5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 41.

6. Pull only light loads.

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

PVT Break-in (Clutches/Belt)

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

40

OPERATION

Pre-Ride Inspection

WARNING

If a proper inspection is not done before each use, severe injury or death
could result. Always inspect the vehicle before each use to ensure it's in
proper operating condition.

Item Remarks Page

Brake system/pedal travel Ensure proper operation 30

Brake fluid Ensure proper level 87

Front suspension Inspect, lubricate if necessary 63

Rear suspension Inspect, lubricate if necessary 63

Seat belts Inspect for wear or damage 22

Steering Ensure free operation 89

Tires Inspect condition and pressure 91

87

Wheels/fasteners Inspect, ensure fastener tightness 91

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels

33
66

Coolant level Ensure proper level 78

79

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 85

Indicator lights/switches Ensure proper operation 27

Air filter, pre-filter Inspect, clean 83

Air box sediment tube Drain deposits whenever visible 83

Headlights Ensure proper operation 94

Brake light/taillight Ensure proper operation 95

41

OPERATION

Starting the Engine

WARNING

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

CAUTION

Operating the vehicle immediately after starting could cause engine damage.
Allow the engine to warm up for several minutes before operating the vehicle.

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

2. Apply the brakes. Engage the park brake.

3. Shift the transmission to neutral.

NOTE: Do not press the throttle pedal while starting the engine.

4. MVRS 800: Move the ignition switch lever to the ON position to
activate the fuel pump. Move the ignition switch lever past the ON
position to the point of starter engagement, then release the lever.
The starter will engage for a pre-set time period. If the engine does
not start within the pre-set time period, the starter will disengage.
Return the lever to the OFF position and wait five seconds before
attempting to start again. Repeat this procedure until the engine
starts.

5. MVRS 700: Move the ignition switch lever past the ON/RUN posi­tion to START. Engage the starter for a maximum of five seconds,
releasing the lever when the engine starts. If the engine does not
start within five seconds, release the ignition switch lever and wait
five seconds. Repeat this procedure until the engine starts.

42

OPERATION

Braking

1. Release the throttle pedal completely.

2. Press on the brake pedal evenly and firmly.

NOTE: Practice starting and stopping (using the brakes) until you're familiar

with the controls.

NOTE: When the throttle pedal is released completely and the engine speed

drops near an idle, the vehicle has no engine braking.

WARNING

Failure to allow for increased braking distance when hauling cargo or towing
a trailer may result in accident and injury. Always slow down and allow
additional braking distance when towing or hauling cargo.

Stopping the Engine

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

2. Turn the ignition switch lever off to stop the engine.

3. Engage the park brake.

WARNING

A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine.

43

OPERATION

Driving Safely

Driving Procedure

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

2. After starting the engine and allowing it to warm up, apply the ser­vice brakes, and shift the transmission into gear.

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

4. Release the park brake.

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

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

NOTE: Low gear is the primary range for operating this vehicle. High gear is

intended for use on hard-packed surfaces with light loads.

44

OPERATION

Driving Safely

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

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

3. Correct a skid by turning the steering wheel in the direction of the
skid.

4. Drive with AWD engaged to assist in controlling the vehicle.

CAUTION

Severe damage to the drive train may occur if the AWD is engaged while the
wheels are spinning. Always allow the wheels to stop spinning before
engaging AWD.

WARNING

Failure to exercise care when operating on slippery surfaces can result in
loss of tire traction and cause loss of control, accident, and serious injury or
death.

Never apply the brakes during a skid.
Do not operate on excessively slippery surfaces.
Always reduce speed and use additional caution when operating on slippery

surfaces.

45

OPERATION

Driving Safely

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always travel
straight uphill.

2. Avoid steep hills

(15° maximum)
unless you have
received proper
training from a
certified training
instructor. Contact
a Polaris Defense
representative (see
page 1).

3. Keep both feet on

the floor.

15° maximum

4. Proceed at a steady rate of speed and throttle opening.

WARNING

Climbing hills improperly can cause loss of control or vehicle overturn.
Always check the terrain carefully before climbing a hill.

Braking and handling are greatly affected when operating in hilly terrain.
Improper procedure could cause loss of control or overturn and result in
serious injury or death.

Avoid steep hills (15° maximum) unless you have received proper training
from a certified training instructor.

Use extreme caution when operating on hills, and follow proper operating
procedures outlined in the owner's manual.

Never climb hills with excessively slippery or loose surfaces.
Never open the throttle suddenly.
Never go over the crest of a hill at high speed. An obstacle, a sharp drop, or

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

46

OPERATION

Driving Safely

Driving on a Sidehill (Sidehilling)

WARNING

Crossing hillsides or turning on hills can result in loss of control or vehicle
overturn, resulting in severe injury or death. Avoid crossing the side of a hill
when possible. When unavoidable, exercise extreme caution. Avoid steep
hills (15° maximum) unless you have received proper training from a certified
training instructor.

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Proceed directly downhill.

2. Slow down.

3. Apply the brakes slightly to aid in slowing.

WARNING

Traveling downhill improperly could cause loss of control or vehicle overturn.
Always check the terrain carefully before descending a hill.

Never descend a hill at high speed. Excessive speed may result in loss of
vehicle control and lead to serious injury or death. Always operate slowly
when traveling downhill.

Avoid descending a hill at an angle, which would cause the vehicle to lean
sharply to one side. Travel straight downhill when possible.

Avoid steep hills (15° maximum) unless you have received proper training
from a certified training instructor.

47

OPERATION

Driving Safely

Driving Through Water

WARNING

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

Your Polaris vehicle
can operate through
water up to a maximum
recommended depth
equal to the floor­boards. Follow these
procedures when oper­ating through water:

1. Always determine
water depths and
current before
entering.

2. Choose a crossing

where both banks

Floorboard

have gradual
inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After leaving water, always dry the brakes by applying light pres-

sure to the pedal repeatedly until braking action is normal.

NOTE: After running your vehicle in water, it's critical that you perform the ser-

vices outlined in the Periodic Maintenance Chart beginning on page

59. Give special attention to engine oil, transmission oil, front and rear
gearcases, and all grease fittings.

CAUTION

Immersion can result in major damage if the vehicle isn't serviced correctly
and promptly. After immersion, always take the vehicle to a Polaris Defense
service technician for service. Do not start the engine!

If it's impossible to bring the vehicle to a Polaris Defense service technician
before starting the engine, perform the service outlined on page 93, and take
the vehicle to your technician at the first opportunity.

48

Driving Safely

Driving Over Obstacles

OPERATION

Be alert! Look ahead and learn to read the terrain you're traveling on.
Watch for hazards such as logs, rocks and low hanging branches.

WARNING

Severe injury or death can result if your vehicle suddenly comes in contact
with a hidden obstacle. Not all obstacles are immediately visible. Reduce
speed and travel with caution in unfamiliar terrain.

49

OPERATION

Driving Safely

Driving in Reverse

Follow these guidelines when operating in reverse:

1. Back slowly.

2. Apply the brakes lightly for stopping.

3. Avoid turning at sharp angles.

4. Always avoid backing downhill.

5. Never open the throttle suddenly while backing.

6. Always inspect left and right fields of vision before backing.

WARNING

Failure to use caution when operating in reverse can result in serious injury
or death. Before shifting into reverse, always check for obstacles or people
behind the vehicle and follow the reverse operation procedures outlined in
this manual. Always back slowly.

50

Driving Safely

Parking on an Incline

OPERATION

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

1. Place the transmission in gear.

2. Apply the brakes. Turn the engine off.

3. Engage the park brake.

4. Block the rear wheels on the downhill side.

WARNING

A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine. Always block the downhill
side of the wheels if leaving the vehicle on a hill, or park the vehicle in a
sidehill position instead.

Operating the vehicle while the park brake is engaged could cause loss of
control and result in serious injury or death. Always disengage the park brake
before operating the vehicle.

51

OPERATION

Driving Safely

Hauling Cargo

WARNING

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

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.

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

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

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 mph (16 kph) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing
loads in rough terrain, while cornering, or while ascending or descending a
hill.

52

OPERATION

Driving Safely

Hauling Cargo

This vehicle has been designed to carry or tow specific capacities.
Always read and understand the load distribution warnings listed on the
warning labels and in the owner’s manual. Never exceed the following
capacities.

Model Maximum Capacity

(Level Ground)

MVRS 4X4 700
MVRS 4X4 800

MVRS 6X6 700
MVRS 6X6 800

Driving with
passengers in the rear
box can result in
severe injury or death.

Passengers must
always ride in the cab
or in a properly
installed jump seat
with seat belts
fastened securely.
Never allow
passengers to ride in
the rear box.

1600 lbs. (726 kg) 1000 lbs. (454 kg) 100 lbs. (45 kg)

1800 lbs. (816 kg) 1200 lbs. (544 kg) 100 lbs. (45 kg)

Cargo Box Front Rack

WARNING

53

OPERATION

Driving Safely

Dumping the Cargo Box

WARNING

Operating the vehicle while the cargo box is raised could result in severe
injury. The box could close unexpectedly and cause injury to the driver or
passenger. The rear tires will also catch the rear of a raised box, damaging
the vehicle and creating hazardous driving conditions. Never operate this
vehicle with the cargo box in the raised position.

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.

Engage the park
brake.

3. Dismount the

vehicle.

Release Lever

4. Ensure that the cargo

is positioned evenly
or toward the front of the cargo box.

5. Release the tailgate latches and lower the tailgate.

6. Stand clear and push downward on the cargo box release lever.

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

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

WARNING

If the weight distribution on the box is located toward the 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.

54

OPERATION

Driving Safely

Towing Loads

WARNING

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

Never load more than 150 lbs. (68 kg) tongue weight on the towing bracket.
Do not operate the vehicle faster than 10 mph (16 km/h) when towing. See

page 52. Towing a trailer increases braking distance.
Do not tow more than the recommended weight for the vehicle.
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.
Never tow a trailer on a grade steeper than 15°.

Model Total Towed

Load Weight

(Level Ground)

All 1750 lbs.

(794 kg)

To t al To w e d

Load Weight

(15° grade)

850 lbs.

(386 kg)

Total Hitch

Vertical

Weight

150 lbs.

(68 kg)

Maximum

Towing

Speed

10 mph

(16 kph)

Belt Life

To extend belt life, use the lowest gear possible when hauling or towing
heavy cargo.

55

OPERATION

Driving Safely

Parking the Vehicle

WARNING

A rolling vehicle can cause property damage and serious injury. Always
engage the park brake after stopping the engine.

1. Apply the brakes. Stop the vehicle on a level surface.

2. Turn the engine off.

3. Engage the park brake.

WARNING

Fuel is extremely flammable and can be explosive under certain conditions.
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.

56

All Wheel Drive (AWD)

OPERATION

Press the top of the rocker switch to 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 (and 6X6 center wheels)
will automatically engage any time the rear wheels lose traction. When
the rear wheels regain traction, the front wheels (and 6X6 center wheels)
will automatically disengage. There is no limit to the length of time the
vehicle may remain in AWD.

The AWD switch may be turned on or off while the vehicle is moving. If
the switch is turned off while the front hubs are driving, they will not
release until the rear wheels regain traction.

CAUTION

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

Disengaging AWD

Under certain conditions, it may be possible for the front gearcase to
remain locked unnecessarily. This condition causes increased steering
effort and some vehicle speed restriction. If the front gearcase remains
locked after following these instructions, return the vehicle to a Polaris
Defense service technician for service.

1. Stop the vehicle.

2. Operate in reverse for at least 10 feet.

3. Stop completely.

4. Shift into low gear and drive forward.

57

OPERATION

All Wheel Drive (AWD)

Locking the Differential

CAUTION

Damage to the differential can occur if it is engaged while the vehicle is
traveling at high speeds or while the rear wheels are spinning. Slow the
vehicle to nearly stopped before engaging the differential.

Locking the differential in slippery or low traction conditions helps
improve traction.
to lock the differential and operate in rear wheel drive. On 6X6 models,

all four rear wheels will be drive wheels.

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 turf driving or whenever aggressive traction is not
required. On 6X6 models, the center wheels will remain drive wheels.

Move the rocker switch to the center position (2WD)

4X4 Models

6X6 Models

58

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on
page 113.

NOTE: Service and adjustments are important for proper vehicle operation. If

you're not familiar with safe service and adjustment procedures, have
a Polaris Defense service technician perform these operations.

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

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

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

59

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

Q Have a Polaris Defense service technician perform these services.

WARNING

Improperly performing the procedures marked with a Q could result in
component failure and lead to serious injury or death. Have an authorized
Polaris Defense service technician perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Q Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride -
X Brake pedal travel

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -
X Air filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant
(if applicable)

Headlamp/tail
lamp

X Air filter,

main element

Brake pad wear 10 H Monthly - Inspect periodically

X

Q

Battery 20 H Monthly - Check terminals; clean; test

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check operation; apply

- Weekly - Inspect; replace as needed

ed. See Pre-Ride Checklist
on page 41.

as needed

coolant every 2 years

dielectric grease if replacing

Remarks

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

Q Have an authorized Polaris Defense service technician perform these services.

60

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

X Front Gearcase Oil 25 H Monthly - Inspect level; change yearly
X Middle Gearcase

Oil (6X6)

X Rear gearcase oil 25 H Monthly - Inspect level; change yearly
X Transmission oil 25 H Monthly - Inspect level; change yearly
X Engine breather

filter (if equipped)

X Engine oil change

(break-in)

Park brake cable
tension

X General

lubrication

Shift Linkage 50 H 6 M - Inspect, lubricate, adjust

Q

Steering 50H 6 M - Lubricate

X Front Suspension 50 H 6 M - Lubricate
X Rear Suspension 50 H 6 M - Lubricate

Q Throttle cable/

ETC switch

Throttle body air
intake ducts/flange

Drive belt 50 H 6 M - Inspect; adjust; replace as

Cooling system
(if applicable)

Park brake cable
tension

X Engine oil change 100 H 6 M - Also perform a break-in oil

X Oil filter change 100 H 6 M - Replace with oil change

25 H Monthly - Inspect level; change yearly

25 H Monthly - Inspect; replace if necessary

25 H 1 M - Perform a break-in oil change

at one month

25 H 1 M - Check tension, adjust

50 H 3 M - Lubricate all fittings, pivots,

cables, etc.

50 H 6 M - Inspect; adjust; lubricate;

replace if necessary

50 H 6 M - Inspect duct for proper seal-

ing/air leaks

needed

50 H 6 M - Inspect coolant strength

seasonally; pressure test
system yearly

100 H 6 M - Check tension, adjust

change at one month

Remarks

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

Q Have an authorized Polaris Defense service technician perform these services.

61

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Q Fuel system 100 H 12 M - Check for leaks at tank cap,

lines, fuel valve, filter, pump,
throttle body; replace lines
every two years

Q

Fuel filter 100 H 12 M - Replace yearly

X Radiator

(in applicable)

X Cooling Hoses 100 H 12 M - Inspect for leaks
X Engine mounts 100 H 12 M - Inspect

Exhaust muffler/
pipe

X Spark plug 100 H 12M - Inspect; replace as needed

Q Ignition timing 100 H 12 M - Inspect

X Wiring 100 H 12 M - Inspect for wear, routing,

Q Clutches (drive

and driven)

Q Front wheel

bearings

Q Brake fluid 200 H 24 M - Change every two years

X Seat belts 200 H 24 M - Change every two years

Spark arrestor 300 H 36 M - Clean out

Idle speed - Adjust as needed

Q Toe adjustment - Inspect periodically; adjust

Q

Auxiliary brake (if

X

equipped)

Headlight aim - Adjust as needed

100 H 12 M - Inspect; clean external

surfaces

100 H 12 M - Inspect

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

100 H 12 M - Inspect; clean; replace worn

parts

100 H 12 M - Inspect; replace as needed

when parts are replaced

- Inspect daily; adjust as
needed

Remarks

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

Q Have an authorized Polaris Defense service technician perform these services

62

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 59, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 PLUS 2W-50 Add to proper level on dipstick.

See page 66.

Brake Fluid DOT 4 Maintain level between fill lines.

Main Gearcase Oil
(Transmission)

Front Gearcase Oil Premium Demand Drive Hub

Middle Gearcase Oil
(6X6 only)

Rear Gearcase Oil Premium ATV Angle Drive

Prop Shaft U-joints Polaris Premium U-Joint

Front Prop Shaft Yoke Polaris Premium U-Joint

Ball Joint Polaris Premium all Season

Premium AGL Synthetic
Gearcase Lube

Fluid

Premium ATV Angle Drive
Fluid

Fluid

Lube

Lube

Grease or grease conform­ing to NLGI No. 2

See page

See page

See page

See page 72.

See page

Locate fittings and grease. See
page 64.

Locate fittings and grease
(3 pumps maximum). See page

64.

Locate fitting (back side of
struts), grease with grease gun.
See page 64.

87.

69.

71.

73.

63

MAINTENANCE

Lubrication Recommendations

Prop Shaft

U-Joints

6X6

4X4
6X6

4X4
6X6

Ball Joint

64

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 59. Always change the
oil filter whenever changing oil.

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn­thetic 2W-50 4-cycle oil or a similar oil. See page 108 for the part num­bers of Polaris products.

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine
damage. Always use the recommended oil. Never mix oil brands.

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.

65

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 59. Always use the recommended
engine oil.

Oil Check

The oil dipstick and fill tube is
located on the engine.

1. Position the vehicle on a level
surface.

2. Apply the brakes. Start the

engine and allow it to idle for
20-30 seconds. Stop the engine.

3. Lift the lever lock to remove the

dipstick. Wipe it dry with a clean
cloth.

4. Reinstall the dipstick completely,

but do not lock it. The dipstick
must be screwed completely in
to keep the angle and depth of
the stick consistent.

5. Remove the dipstick and check

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

NOTE: 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.

Dipstick

Safe

Range

{

Check Level

on Top Side

Safe

6. After reinstalling the dipstick, be

sure to seat the lever lock.

66

MAINTENANCE

Engine Oil

Oil and Filter Change

CAUTION

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

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 59. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

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

3. Clean the area around the drain plug.

4. Place a drain pan under the crankcase.

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

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

NOTE: 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 20 ft. lbs. (27 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. Lubricate the o-ring on the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition.

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

67

MAINTENANCE

Engine Oil

Oil and Filter Change

12. Remove the dipstick and fill the sump with two quarts (1.9 l) of rec­ommended oil.

13. Shift the transmission to neutral.

14. Apply the brakes. Engage the park brake.

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

16. Stop the engine. Inspect for leaks.

17. Check the oil level on the dipstick and add oil as necessary to bring
the level to the upper mark on the dipstick.

18. Dispose of used filter and oil properly.

Gearcases

Gearcase Specification Chart

Gearcase Lubricant Capacity Fill Plug

To r q u e

Main Gearcase

(Transmission)

Front Gearcase Premium Demand

Middle Gearcase

(6X6)

Rear Gearcase

(4X4 and 6X6)

Premium AGL

Synthetic

Gearcase Lube

Drive Hub Fluid

Premium ATV

Angle Drive Fluid

Premium ATV

Angle Drive Fluid

15.2 oz.
(450 ml)

5 oz.

(150 ml)

6.75 oz.
(200 ml)

18 oz.

(532 ml)

14 ft. lbs.

(19.4 Nm)

8-10 ft. lbs.

(11-13.6 Nm

14 ft. lbs.

(19.4 Nm)

40-50 ft. lbs.

(54-68 Nm

Drain Plug

To r q u e

14 ft. lbs.

(19.4 Nm)

11 ft. lbs.

(15 Nm)

14 ft. lbs.

(19.4 Nm)

30-45 in. lbs.

(3-5 Nm)

68

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 59. Maintain the
oil level even with the bottom of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 68 for recommended
lubricants, capacities and torque specifications. See page 108 for the
part numbers of Polaris products.

The fill plug is located at the rear of the vehicle.

Oil Check

1. Position the vehicle on a level
surface.

2. Remove the fill plug.

3. Check the oil level.

4. Add the recommended oil as

needed.

5. Reinstall the fill plug. Torque

to specification.

Fill Plug

69

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Oil Change

The drain plug is located on the
bottom of the transmission.
Access the drain plug through the
drain hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the
drain plug. Remove the drain
plug. Drain the oil. Dispose
of used oil properly.

3. Wipe the magnetic end of the
drain plug clean to remove
accumulated metallic filings.

4. After the oil has drained com­pletely, install a new sealing
washer.

Drain Plug

5. Reinstall the drain plug.
Torque to specification.

6. Add the recommended oil as needed. Do not overfill.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks.

70

MAINTENANCE

Gearcases

Front Gearcases

Always check and change the front gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 59. Maintain the
oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 68 for recommended
lubricants, capacities and torque specifications. See page 108 for the
part numbers of Polaris products.

The front gearcase fill plug is located on the right side of the front gear­case.

Oil Check

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

4. Reinstall the fill plug. Torque to spec­ification.

Oil Change

1. Support the vehicle securely with a

jackstand.

2. Remove the front tire on the driver's
side.

3. Remove the fill plug.

4. Place a drain pan under the drain plug
on the bottom right-hand side.

5. Remove the drain plug. Drain the oil. Discard used oil properly.

6. Clean the drain plug. Reinstall the drain plug. Torque to specifica­tion.

7. Add the recommended oil.

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

Drain Plug

Fill Plug

71

MAINTENANCE

Gearcases

Middle Gearcase (6X6)

Always check and change the middle gearcase oil at the intervals out­lined in the Periodic Maintenance Chart beginning on page 59. Maintain
the oil level even with the bottom thread of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 68 for recommended
lubricants, capacities and torque specifications. See page 108 for the
part numbers of Polaris products.

The middle gearcase fill plug is located on the side of the gearcase.

Oil Check

1. Position the vehicle on a level sur­face.

2. Remove the fill plug. Check the oil

level.

3. Add the recommended oil as

needed.

4. Reinstall the fill plug. Torque to

specification.

Oil Change

1. Remove the fill plug.

2. Remove the drain plug from the

bottom of the gearcase. Drain the
oil into a drain pan. Discard used
oil properly.

3. Clean and reinstall the drain plug. Torque to specification.

4. Add the recommended fluid.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks

Drain Plug

Fill Plug

72

MAINTENANCE

Gearcases

Rear Gearcase

Always check and change the rear gearcase oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 59.

Refer to the Gearcase Specifications Chart on page 68 for recommended
lubricants, capacities and torque specifications. See page 108 for the
part numbers of Polaris products.

The rear gearcase fill plug is on the driver's side of the rear gearcase.

Oil Check

Maintain the oil level even
with the bottom thread of the
fill plug hole.

1. Position the vehicle on a
level surface.

2. Remove the fill plug.

Check the oil level.

3. Add the recommended oil

as needed.

4. Reinstall the fill plug.

Torque to specification.

Fill Plug

Drain Plug

73

MAINTENANCE

Gearcases

Rear Gearcase

Oil Change

1. Remove the fill plug.

2. Place a drain pan under the drain plug. Remove the drain plug.

3. Drain the oil. Dispose of used oil properly.

4. Clean the drain plug. Reinstall the drain plug. Torque to specifica­tion.

5. Add the recommended oil.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks.

74

MAINTENANCE

Spark Plugs

CAUTION

Using non-recommended spark plugs can result in serious engine damage.
Always use Polaris-recommended spark plugs.

Refer to the service manual for the recommended spark plug type for
your vehicle. Torque spark plugs to specification.

Plug Condition Torque Specification

New Spark Plug 18 ft. lbs. (24 Nm)

Previously Installed Spark Plug 18 ft. lbs. (24 Nm)

Spark Plug Inspection

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 76.

WARNING

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

1. Remove the seat to access the engine compartment.

2. Remove the spark plug cap. Using the spark plug wrench provided
in the tool kit, remove the plug by rotating it counterclockwise.

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

75

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Plug

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

NOTE: The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect throttle body
adjustments.

Wet Fouled Plug

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

76

MAINTENANCE

Cooling System

Operation

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)
excess 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 radiator.

NOTE: 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 that 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. 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. See page 108 for the part numbers of Polaris prod­ucts.

NOTE: Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Any time the cooling system has been drained for maintenance or repair,
replace the coolant. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.

77

MAINTENANCE

Cooling System

Radiator

Always check and clean the screen and radiator fins at the intervals out­lined in the Periodic Maintenance Chart beginning on page 59. 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.

CAUTION

Washing the vehicle with a high-pressure hose could damage the radiator
fins and impair the radiator's effectiveness. Using a high-pressure system is
not recommended.

Coolant Bottle Level

Always check and change

Overflow

Bottle Cap

the coolant at the intervals
outlined in the Periodic
Maintenance Chart begin­ning on page 59. Maintain
the coolant level between the
minimum and maximum
marks on the bottle (when
the fluid is cool).

The overflow bottle is
located in front of the right
front wheel. Remove the
front platform panel to add
coolant. See page 23.

1. Position the vehicle on a level surface.

2. View the coolant level in the overflow
bottle.

Radiator Cap

3. If the coolant level is below the safe
operating range, remove the bottle cap
and use a funnel to add coolant

Overflow

Bottle

through the filler opening. Reinstall
the cap.

NOTE: If coolant must be added often, or if the overflow bottle runs completely

dry, there may be a leak in the system. Have the cooling system
inspected by a Polaris Defense service technician.

78

MAINTENANCE

Cooling System

Radiator Coolant Level

WARNING

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

1. Remove the front platform panel.

2. Slowly remove the radiator cap.

3. View the coolant level through the
opening.

4. Use a funnel and slowly add coolant as
needed.

NOTE: 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.

NOTE: Use of a non-standard pressure cap

will not allow the recovery system to
function properly. Contact Polaris
Defense for the correct replacement
part.

Radiator Cap

79

MAINTENANCE

Polaris Variable Transmission (PVT) System

Belt slip is responsible for creating excessive heat that destroys belts,
wears clutch components and causes outer clutch covers to fail. Switch
to low range while operating at slower speeds to extend the life of the
PVT components (belt, cover, etc.).

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 7 MPH (11 km/h) Low

Towing heavy loads Low

Operating in rough terrain (swamps, mountains, etc.) Low

Operating at speeds greater than 7 MPH (11 km/h) High

80

MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe
injury or death.

Do not modify any component of the PVT system. Doing so may reduce its
strength so that a failure may occur at a high speed. The PVT system has
been precision balanced. Any modification will cause the system to be out of
balance, creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on
clutch components. Extensive engineering and testing has been conducted
to ensure the safety of this product. However, as the owner, you have the
following responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See a Polaris
Defense service technician as outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install
it in any other product.

• Always make sure the PVT housing is securely in place during operation.

81

MAINTENANCE

PVT System

PVT Drying

There may be some instances when water is accidently ingested into the
PVT system. Use the following instructions to dry it out before operat­ing.

1. Loosen the bottom screws that secure the clutch cover.

2. Allow the water to drain.

3. Tighten the screws.

4. Apply the brakes. Start the engine.

5. Engage the park brake.

6. Shift the transmission to neutral.

7. Apply varying throttle for 10-15 seconds to expel the moisture and
air-dry the belt and clutches. Do not hold the throttle wide open for
more than 10 seconds.

8. Allow the engine RPM to settle to idle speed. Apply the service
brakes. Release the park brake and shift the transmission to the low­est available range.

9. Test for belt slippage. If the belt slips, repeat the process.

10. Take the vehicle to a Polaris Defense service technician for service
as soon as possible.

82

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 59.

1. Lift the cargo box to
access the air box.

2. Remove the air box

cover and inspect the
gasket. It should adhere
tightly to the cover and
seal all the way around.

3. Remove the air filter.

4. Do not attempt to clean

the main element.
Install a new air filter.

NOTE: Apply a small amount of general purpose grease to the sealing edges

of the filter before installing.

5. Inspect the air box for oil or water deposits. If present, drain them

into a suitable container.

NOTE: Service the air filter more frequently if the vehicle is operated in wet

conditions or at high throttle openings for extended periods.

Air Filter

Fuel Filter

The in-line fuel filter should be replaced by a Polaris Defense service
technician after every 100 hours of operation and any time the fuel
becomes contaminated with dirt or debris. Do not attempt to clean the
fuel filter.

83

MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor
could result in serious injury or death.

Do not perform service on the spark arrestor while the system is hot. Exhaust
system temperatures can reach 1000° F. Allow components to cool
sufficiently before proceeding.

Remove any combustible materials from the area.
Wear eye protection and gloves.
Do not stand behind or in front of the vehicle while purging.
Never run the engine in an enclosed area. Exhaust contains poisonous

carbon monoxide gas that can cause loss of consciousness or death in a
very short time.

Never go under the vehicle while it's inclined.

Use the following procedure to periodically purge accumulated carbon
from the exhaust pipe.

1. Remove the arrestor clean-out
plugs located on the bottom of
the muffler.

2. Shift the transmission to neutral.

Apply the brakes. Start the
engine.

3. Purge accumulated carbon from

the system by momentarily rev­ving the engine several times.

4. If carbon is expelled, cover or

Exhaust

Outlet

Clean-Out

Plugs

plug the exhaust outlet and rap
on the pipe around the clean-out
plugs while revving the engine several more times.

5. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot higher than the front. Apply the brakes. Engage
the park brake. Block the wheels. Make sure the transmission is in
neutral and repeat steps 3 and 4 until no more particles are expelled
when the engine is revved.

6. Stop the engine. Allow the arrestor to cool.

7. Reinstall the arrestor plugs and remove the outlet cover or plug.

84

MAINTENANCE

Throttle System

WARNING

Failure to check or maintain proper operation of the throttle system can result
in an accident and lead to serious injury or death if the throttle pedal sticks
during operation.

Never start or operate this vehicle if it has a sticking or improperly operating
throttle pedal.

Immediately contact a Polaris Defense service technician for service if
throttle problems arise.

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

Throttle Freeplay

If the throttle pedal has excessive
play due to cable stretch or mis­adjustment, it will cause a delay
in throttle response, especially at
low engine speed. The throttle
may also not open fully. If the
throttle pedal has no freeplay, the
throttle may be hard to control,
and the idle speed may be erratic.

Check the throttle pedal freeplay
at the intervals outlined in the

Throttle

Pedal

Periodic Maintenance Chart
beginning on page 59. Adjust the
freeplay if necessary.

Throttle Freeplay Inspection

1. Apply the brakes. Engage the park brake. Shift the transmission to
neutral.

2. Start the engine. Allow it to warm up thoroughly.

3. Measure the distance the throttle pedal moves before the engine

begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.6-

3.2 mm).

85

MAINTENANCE

Throttle System

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see a Polaris Defense service technician for adjust­ment.

Throttle Freeplay Adjustment

1. Remove the seat.

2. Locate the throttle cable
adjuster.

3. Squeeze the end of the rub­ber boot and slide it far
enough to expose the end
of the inline cable adjuster.

4. Loosen the adjuster lock
nut.

Boot

5. Rotate the boot to turn the
adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the throttle
pedal. See page 85.

NOTE: While adjusting, lightly flip the throttle pedal up and down.

6. Tighten the lock nut.

7. Squeeze the end of the rubber boot and slide it over the cable
adjuster to its original position.

Lock Nut

Adjuster

86

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes activated by the
brake pedal. See page 30.

Brake Fluid

Inspect the brake system

Brake Fluid

Reservoir

routinely. Inspect the level of the
brake fluid before each
operation.

Change the brake fluid every
two years and any time the fluid
becomes contaminated, the fluid
level is below the minimum, or if
the type and brand of the fluid in
the reservoir are unknown.

1. Position the vehicle on a
level surface.

2. Remove the brake fluid access panel on the dash at the left side of

the steering wheel. View the brake fluid level at the reservoir. The
level should be between the upper (MAX) and lower (MIN) level
lines.

3. If the fluid level is lower than the upper level line, add brake fluid to

the upper (MAX) line.

4. Apply the brake forcefully for a few seconds and check for fluid

leakage around the fittings.

WARNING

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

87

MAINTENANCE

Brakes

Brake Inspection

1. Check the brake system for
fluid leaks.

2. Check the brake pedal for

excessive travel or a spongy
feel.

3. Check the friction pads for

wear, damage and looseness.

4. Inspect the brake disc spline

and pad wear surface for
excessive wear.

5. Change pads when worn to

3/64" (1 mm).

Park Brake Inspection

3/64" (1mm)

1. Apply the brakes.

2. Pull the park brake lever downward as far as possible.

3. Check the vehicle for movement. The vehicle should not roll while

parked. If the vehicle moves, adjust the park brake.

Park Brake Cable Tension

Inspect and adjust park brake cable tension after the first 25 hours of
operation and every 100 hours thereafter to ensure proper cable tension.

NOTE: Loss of tension in the park brake cable may cause illumination of the

park brake light and activation of the limiting feature. If this occurs,
inspect and adjust park brake cable tension. If performing this service
is difficult due to conditions or location, open the hood and temporarily
disconnect the park brake connector. This will inactivate the limiting
function. Reconnect the connector as soon as possible, and adjust the
park brake cable to proper tension.

1. Position the vehicle on a level surface.

2. Shift the transmission to neutral.

3. Loosen or tighten the nuts on the lever end of the park brake cable

as needed.

88

MAINTENANCE

Steering Wheel Inspection

Check the steering wheel for specified freeplay and smooth operation at
the intervals outlined in the Periodic Maintenance Chart beginning on
page 59.

1. Position the vehicle on level ground.

2. Lightly turn the steering wheel left and right.

3. There should be 0.8"-1.0" (20-25 mm) of freeplay.

4. If there is excessive freeplay or strange noises, or the steering feels
rough or "catchy," have the steering system inspected by an autho­rized Polaris Defense service technician.

89

MAINTENANCE

Suspension Adjustment

The rear suspension may be adjusted to provide a stiffer suspension if
necessary.

1. Remove the top shock mounting bolts from the inside mounting
holes.

2. Reposition the shocks to the outside mounting holes.

3. Reinstall the shock mounting bolts. Torque to 30 ft. lbs. (40 Nm).

Outside Mounting Holes

Inside Mounting Holes

Cam

Rear Spring Adjustment

The rear shock absorber springs are adjusted by rotating the adjustment
cam either clockwise or counterclockwise to increase or decrease spring
tension.

90

MAINTENANCE

Tires

WARNING

Operating your vehicle with worn tires will increase the possibility of skidding,
loss of control and an accident, which could result in serious injury or death.
Always replace tires when the tread depth measures 1/8" (3 mm) or less.

Improper tire inflation or the use of non-standard size or type of tires may
adversely affect vehicle handling, which could result in vehicle damage or
personal injury. Always maintain proper tire pressure. When replacing tires,
always use original equipment size and type.

Tire Tread Depth

Always replace tires

1/8" (3 mm)

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

Axle and Wheel Nut Torque Specifications

Inspect the following items occasionally for tightness, and if they've
been loosened for maintenance service.

Nut Type Location Nut Torque

2-Piece Flange
Nut

Spindle Nut Front 70 ft. lbs. (95 Nm)

Hub Retaining Nuts Center and Rear 110 ft. lbs. (150 Nm)

NOTE: Do not lubricate the stud or the lug nut.

Front and Rear 35 ft. lbs. (47 Nm)

91

MAINTENANCE

Tires

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle
handling, which can result in serious injury or death. Always ensure that all
nuts are torqued to specification. Do not service axle nuts that have a cotter
pin installed. See a Polaris Defense service technician.

Wheel Removal

1. Apply the brakes. Stop the engine. Place the transmission in gear.
Engage the park brake.

2. Loosen the wheel nuts slightly.

3. Elevate the side of the vehicle by placing a suitable stand under the

frame.

4. Remove the wheel nuts and washers. Remove the wheel.

Wheel Installation

1. Apply the brakes.

2. Place the transmis-

sion in gear.

3. Engage the park

brake.

4. Place the wheel in

the correct posi­tion on the wheel
hub. Be sure the
valve stem is
toward the outside
and rotation
arrows on the tire
point toward for­ward rotation.

5. Attach the wheel nuts and washers and finger tighten.

6. Carefully lower the vehicle to the ground.

7. Torque the wheel nuts to specification. See page 91.

92

MAINTENANCE

Vehicle Immersion

CAUTION

If your vehicle becomes immersed, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to a Polaris Defense
service technician before starting the engine.

If it's impossible to take your vehicle to a Polaris Defense service tech­nician before starting it, follow the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the
footrests.

2. Dry any water present in the air box.

3. Filter replacement is required if water is present.

4. Remove the front dash panel. See page 23.

5. Thoroughly dry the air pre-cleaner.

6. Remove the spark plugs.

7. Turn the engine over several times using the electric start.

8. Dry the spark plugs and reinstall, or replace with new plugs.

NOTE: Attempt to start the engine. If necessary, repeat the drying procedure.

9. Take the vehicle to a Polaris Defense service technician for service

as soon as possible, whether you succeed in starting it or not.

NOTE: If water has been ingested into the PVT follow the procedure on page

82 for drying.

93

MAINTENANCE

Lights

When servicing a halogen lamp, don't touch the lamp with bare fingers.
Oil from your skin leaves a residue, causing a hot spot that will shorten
the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and
taillight lenses become dirty during normal operation. Wash the headlights
frequently to maintain lighting quality.

Hot components can cause serious burns to skin. Do not service the
headlamps until they've cooled sufficiently.

Headlight Lamp Replacement

1. Rotate the back of the headlight
harness and pull the harness
assembly away from the head­light assembly.

2. Remove the headlamp.

3. Apply dielectric grease to the

socket and install the new lamp.

4. Reinstall the harness assembly

into the headlight assembly.
Rotate the harness to lock the
assembly in place.

Harness

94

Lights

MAINTENANCE

Headlight Beam Adjustment

1. Loosen the headlamp mounting
bolt.

2. Tilt the headlamp upward or down-

ward.

3. Tighten the bolt.

Mounting Bolt

Brake Lights

When the brake pedal is depressed, the console brake light comes on.
Check the brake light before each ride.

1. Turn the ignition switch to the ON position.

2. Depress the brake pedal. The brake light should come on after about

10 mm (0.4 in.) of pedal travel. If the light doesn't come on, check
the bulb.

95

MAINTENANCE

Battery

Your vehicle may have either a sealed battery, which requires little
maintenance, or a conventional battery. A sealed battery can be identi­fied by its flat covers on the top of the battery. A conventional battery
has six filler caps on the top of the battery.

Conventional Battery

Always keep battery terminals and connections free of corrosion. If
cleaning is necessary, remove the corrosion with a stiff wire brush.
Wash with a solution of one tablespoon baking soda and one cup water.
Rinse well with tap water and dry off with clean shop towels. Coat the
terminals with dielectric grease or petroleum jelly. Be careful not to
allow cleaning solution or tap water into the battery.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can
result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.
Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.
Eyes: Flush with water for 15 minutes and get prompt medical attention.
Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc.

away. Ventilate when charging or using in an enclosed space. Always shield
eyes when working near batteries. KEEP OUT OF REACH OF CHILDREN.

96

MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an
explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the
battery, always connect the negative (black) cable last.

Battery Removal

1. Remove the front dash
panel. See page 23.

2. On conventional batteries,

remove the battery vent
tube.

3. Disconnect the black

(negative) battery cable
first.

4. Disconnect the red

(positive) battery cable last.

5. Remove the battery retainer

bracket bolt and remove the
bracket.

Battery

Retainer

Bracket Bolt

6. Lift the battery out of the

vehicle. Be careful not to tip
a conventional battery sideways, which could spill electrolyte.

CAUTION

If electrolyte spills, immediately wash it off with a solution of one tablespoon
baking soda and one cup water to prevent damage to the vehicle.

97

MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat­tery and result in a shorter life. It can also hinder vehicle performance.
Follow the battery charging instructions on page 100 before installing
the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat­teries do not have a vent tube).

NOTE: The vent tube must be free of obstructions and securely installed.

Route the tube away from the frame and vehicle body to prevent con-

tact with electrolyte.

WARNING

Battery gases could accumulate in an improperly installed vent tube and
cause an explosion, resulting in serious injury or death. Always ensure that
the vent tube is free of obstructions and is securely installed as
recommended.

4. Install the battery retainer bracket and secure the bolt.

5. On conventional batteries, coat the terminals with dielectric grease
or petroleum jelly.

6. Connect and tighten the red (positive) cable first.

7. Connect and tighten the black (negative) cable last.

8. Verify that cables are properly routed.

9. Reinstall the front dash panel.

98