Polaris M1400 Owner's Manual

POLARIS M1400

Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions

and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

1

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

•RZR® sport vehicles

• VICTORY® motorcycles

• INDIAN® motorcycles

• GEM® electric vehicles
We believe POLARIS sets a standard of excellence for all utility and recreational vehicles

manufactured in the world today. Many years of experience have gone into the engineering,
design, and development of your POLARIS vehicle, making it the finest machine 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.

Your manual contains instructions for minor maintenance, but information about major
repairs is outlined in the POLARIS Service Manual and can be performed by a factory
certified Master Service Dealer® (MSD) Technician.

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

2

POLARIS® is a trademark of POLARIS Industries Inc.
Copyright 2015 POLARIS Industries Inc. All information contained within this publication is based on the latest

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

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

Printed in U.S.A.
2016 POLARIS M1400 Owner’s Manual
P/N 9926638

3

TABLE OF CONTENTS

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

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Emission Control Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

POLARIS Products. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

4

INTRODUCTION

The POLARIS M1400 is a utility vehicle. Never operate on public roads. This vehicle does
not meet National Highway Traffic Safety Administration (NHTSA) regulations for opera­tion on public streets, roads and highways. Familiarize yourself with all laws and regulations
concerning the operation of this vehicle in your area.

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

The safety alert symbol indicates a potential personal injury haza rd.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

5

INTRODUCTION

Failure to follow the warnings contained in this manual can result in severe injury or death.
Your POLARIS M1400 is not a toy and can be hazardous to operate. This vehicle handles differently

than other vehicles, such as cars, trucks or other off-road vehicles. A collision or rollover can occur
quickly, even during routine maneuvers like turning, or driving on hill s or over obstacles, if you fail to
take proper precautions.

• Read this owner’s manual and review the safety DVD that came with your vehicle. A free extra copy
of the DVD can be obtained by contacting your local dealer. Understand all safety warnings,
precautions and operating procedures before operating the vehicle. Keep this manual with the
vehicle.

• Review the safety DVD and take the free online Recreational Off-Highway Vehicle Association
(ROHVA) training course at www.rohva.org.

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

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be able to sit
with backs against the seat, both feet flat on the floor and both hands on the steering wheel (if
driving) or on a passenger hand hold.

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

• Always keep hands, feet an d all other body parts inside the vehicle at all times.

• Always wear the proper clothing when operating or riding in this vehicle. All riders should wear
substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye
protection are recommended when appropriate for working or riding conditions.

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

WARNING

6

INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the spaces provided below.
The Vehicle Identification Number (VIN) indicates the model year, model type and serial
number of your vehicle. The VIN is stamped on the left rear frame. The VIN is also on the
manufacturer’s label, which is located under the passenger seat. Gross Vehicle Weight
information for your vehicle is on the Passenger/Tire Pressure Warning Label in the rear
cargo box. See page 10.

To order an extra or replacement key for your vehicle, please contact customer service. Be
prepared to provide your key number and VIN. Remove the spare key and store it in a safe
place. A key can be duplicated only by ordering a key blank (using your key number) and
mating it with one of your existing keys. The key switch must be replaced if all keys are lost.

Vehicle Model Number: ________________________________________________________________________

Frame VIN: _________________________________________________________________________________

Motor Serial Number (on side of motor): ___________________________________________________________

Key Number: ________________________________________________________________________________

Frame VIN

Key

Number

####

7

INTRODUCTION

European Vibration and Noise

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

The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environment was controlled as indicated by the

test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

8

SAFETY

Safety Labels and Locations

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

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

Proper Use Warning

Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

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

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

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

• Do not exceed seating capacity: 2 occupants.

7179978

Clutch Cover Warning

WARNING

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

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

7175488

Discretionary

Warning

Proper Use

Warning

Shift Caution

Clutch Cover Warning

9

SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING

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

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

• After or while using Alcohol or Drugs.

• On extreme off-road terrain or extreme slopes.

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

• With more than one passenger, or a passenger under age twelve or who cannot comfortably reach
the floor and hand holds.

• With non-POLARIS approved accessories - they may seriously affect stability.

ALWAYS:

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

• Wear eye protection and keep hands and feet in vehicle at all times. Wear a helmet when appropriate.

• Reduce speed and use extra caution when carrying a passenger.

• Avoid sharp turns or turns while applying heavy throttle.

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

• Make sure passenger reads and understands all safety labels.

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

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

7180694

Shift Caution

CAUTION

To avoid transmission damage, shift only when vehicle is stationary and at idle.
APPLY BRAKE TO START. When this vehicle is not in operation or unattended, place shift in the park

position.

7181060

10

SAFETY

Safety Labels and Locations

Passenger/Tire Pressure Warning

WARNING

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

• Never carry passengers in cargo box.

WARNING

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

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

• Overloading or carrying tall, off-center, or
unsecured loads will increase your risk of losing
control. Loads should be centered and carried as
low as possible in box.

• For stability on rough or hilly terrain, reduce speed and cargo.

• Be careful if load extends over the side of the box.

7181551

Personal Protective Equipment

Always wear the proper clothing when operating or riding in this vehicle. All riders should
wear substantial footwear, long pants and a close-fitt ing shirt. A hard hat or helmet and
approved eye protection are recommended when appropriate for working or riding
conditions. POLARIS recommends wearing approved eye protection bearing markings such
as VESC 8, V-8, Z87.1 or CE. Never operate or ride in this vehicle while barefoot or while
wearing sandals or tennis shoes.

Workplace safety regulations may require the use of safety glasses, safety shoes and a hard
hat or helmet. Familiarize yourself with local requirements, be prepared for operating condi­tions and wear the appropriate safety gear.

M1400 BASE BASE WITH

SIDES

BASE WITH V AN

ENCLOSURE

TIRE PRESSURE IN PSI (KPa) FRONT 32 (220)

REAR 32 (220)

FRONT 32 (220)

REAR 32 (220)

FRONT 32 (220)

REAR 32 (220)

VEHICLE OPERATING WEIGHT 1060 lbs.

(481 kg)

1115 lbs.

(506 kg)

1185 lbs.

(538 kg)

MAXIMUM CARGO PAYLOAD 1100 lbs.

(499 kg)

1045 lbs.

(474 kg)

975 lbs.
(442 kg)

GVW = VEHICLE + OCCUPANTS +
PAYLOAD + ACCESSORIES

2510 lbs.
(1139 kg)

2510 lbs.

(1139 kg)

2510 lbs.

(1139 kg)

Read Operation and Maintenance Manual for more detailed loading information.

Passenger/Ti re Pressure

Warning

11

SAFETY

Operator Safety

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 entire manual and all labels carefully. Follow the operating procedures

described.

• Never allow anyone under the age of 16 to operate this vehicle and never allow anyone

without a valid driver's license to operate this vehicle.

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

vehicle.

• No person under the age of 12 may ride as a passenger in this vehicle. All riders must be

able to sit with backs against the seat, both feet flat on the floor and both hands on the
steering wheel (if driving) or on a passenger hand hold.

• All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard hat

or helmet and approved eye protection are recommended when appropriate for working or
riding conditions. Seat belt must be worn at all times.

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

• Always keep both hands on the steering wheel and both feet on the floorboards of the

vehicle during operation.

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

product labels.

• To reduce rollover 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 (unless marked for off-

road use). Always avoid paved surfaces.

• 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 the vehicle before each use to make sure it's in safe operating condition.

Always follow the inspection procedures described in this manual.

WARNING

12

SAFETY

Operator Safety

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

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

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

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

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

• Always follow proper procedures for climbing hills as described in this manual. See page

34. Check the terrain carefully before attempting to climb a hill. Never climb hills with
excessively slippery or loose surfaces. Never apply throttle suddenly. Never 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. See page

34. 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 large rocks or fallen trees. Always follow the proper procedures
outlined in this manual when operating over obstacles. See page

33.

• 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. See page

36. 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 in this manual. Always maintain
proper tire pressure as specified on safety labels.

• Never modify this vehicle through improper installation or use of non-POLARIS
approved 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 place the transmission in PARK before getting out of the vehicle.

13

SAFETY

Operator Safety

• Always stop the engine before refueling. Remove flammable material containers from the

box before filling them with fuel. Make sure the refueling area is well ventilated and free
of any source of flame or sparks. Gasoline is extremely flammable. See page 15 for fuel
safety warnings.

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

by someone under the age of 16 or without a driver’s license and proper training, or
accidental starting.

FOR MORE INFORMATION ABOUT SAFETY,

call POLARIS at 1-800-342-3764.

Gross Vehicle Weight Rating (GVWR)

WARNING! Exceeding the gross vehicle weight rating of your vehicle can reduce stability and handling

and could cause loss of control. NEVER exceed the GVWR of your vehicle.

The maximum payload capacity of your vehicle is the maximum weight you may add to
your vehicle without exceeding the GVWR. This capacity is determined by calculating the
difference between your vehicle’s GVWR and wet weight.

Refer to the specification section of this manual or the Manufacturer’s Label on the vehicle
for model-specific information.

When determining the weight you will be adding to your vehicle, and to ensure you do not
exceed the maximum payload capacity, include the following:

• operator body weight

• passenger body weight

• weight of all occupants’ apparel and items in or on apparel

• weight of any options or accessories and their contents

• weight of any additional cargo on the vehicle

Equipment Modifications

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

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

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

14

SAFETY

Operator Safety

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

Age Restrictions

This vehicle is an ADUL T VEHICLE ONLY. NEVER operate this
vehicle if you are under age 16 and NEVER operate without a
valid driver’s license.

Never operate with a passenger under the age of 12. All riders
must be able to sit with backs against the seat, both feet flat on
the floor and both hands on the steering wheel (if driving) or on a
passenger hand hold.

Protective Apparel

Always wear the proper clothing when operating or riding in this vehicle. All riders should wear
substantial footwear, long pants and a close-fitting shirt. A hard hat or helmet and approved eye
protection are recommended when appropriate for working or riding conditions. POLARIS
recommends wearing approved eye protection bearing markings such as VESC 8, V-8, Z87.1 or CE.
Never operate or ride in this vehicle while barefoot or while wearing sandals or tennis shoes.

Operating Without Instruction

Operating this vehicle without proper instruction increases the risk
of an accident. The operator must understand how to operate the
vehicle properly in different situations and on different types of
terrain.

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

Using Alcohol or Drugs

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

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

Seat Belts

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

All riders must wear seat belts at all times.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds increases the operator's ri sk of losing control. Always
operate at a speed that's appropriate for the traffic, the visibility and operating conditions, your skills
and your passenger’s skills.

WARNING

15

SAFETY

Operator Safety

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

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

• Always use an approved gasoli ne container to store fu el and remove the container from the vehicle

before filling to avoid fuel ignition due to electrical static discharge.

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

where gasoline is stored.

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

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

clothing.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in safe operating condition before operating increases
the risk of an accident. Always perform the pre-ride inspection before each use of your vehicle to make
sure it's in safe operating condition. See page 30.

Always follow all inspection and maintenance procedures and schedules described in this owner's
manual. See page 51.

Operating With a Load on the Vehicle

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

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight capacity is listed in the

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

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

on the vehicle.

Always follow these guidelines:

Operating a Damaged Vehicle

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

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

Passenger and/or cargo exceeds half the maximum weight capacity 1. Slow down.

2. Verify tire pressure.

3. Use extra caution when
operating.

Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing

16

SAFETY

Operator Safety

Operating on Public Roads

This vehicle does not meet National Highway Traffic Safety Administration (NHTSA) regulations for
operation on public streets, roads and highways. Operating this vehicle on public streets, roads or
highways could result in a collision with another vehicle. Never operate this vehicle on any publ ic
street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or rollover. Always follow
proper procedures for turning as described in this owner’s manual. Never turn abruptly or at sharp
angles. Never turn at high speeds. Practice turning at slow speeds before attempting to turn at faster
speeds.

Jumps and Stunts

Exhibition driving increases the risk of an accident or rollover. Never attempt wheelies, jumps,
doughnuts or other stunts. Avoid exhibition driving.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on unfamiliar terrain could result in an accident or rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or
rollover. Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to
changing terrain conditions.

Unauthorized Use of the Vehicle

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

Exposure to Exhaust

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

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

Vehicle Rollover

Vehicle rollover could cause serious injury or death. Always make sure the seat belts are secured for
operator and passenger before operating. Avoid situations that could result in a rollover. Avoid sharp
turns and abrupt steering maneuvers.

Improper Hill Climbing

Climbing hills improperly can cause loss of control or vehicle rollover. Always follow proper procedures
for climbing hills as described in this owner's manual. See page 34.

17

SAFETY

Operator Safety

Descending Hills Improperly

Improperly descending a hill could cause loss of control or rollover. Always follow proper procedures for
traveling down hills as described in this owner’s manual. See page 34.

Stalling While Climbing a Hill

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

If all forward speed is lost:

• Apply the brake s.

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

If you begin rolling downhill:

• Never apply engine power.

• Apply the brakes gra dually until the vehicle is fully stopped.

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

Improper Tire Maintenance

Operating this vehicle with improper tires or with improper or uneven tire pressure could cause loss of
control or accident. Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in the owner's manual and on safety labels.

Operating on Slippery Terrain

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

Skidding or sliding due to loss of traction can cause loss of control or rollover (if tires regain traction
unexpectedly). Always follow proper procedures for operating on slippery surfaces as described in this
owner's manual. See page 32.

Operating on Frozen Bodies of Water

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

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

Hot Exhaust Systems

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

18

FEATURES AND CONTROLS

Component Locations

Console

Hip

Bar

Cargo

Box

Headlights

Front Bumper/Brush Guard

Receiver

Hitch

Tailgate

Taillight

19

FEATURES AND CONTROLS

Console

Instrument Cluster

MODE Button

Gear Selector

Cup Holder

Ignition\Light
Switch

Brake Pedal

Throttle
Pedal

Storage Compartment

Auxiliary
Outlet

Storage Tray

Dump Box Switch

20

FEATURES AND CONTROLS

Console

Auxiliary 12-Volt Terminal Board

The 12-volt terminal board is located under the hood. It contains constant 12-volt, switched
12-volt and ground terminals that can be used to power auxiliary lights and accessories. The
terminals are limited to 10 amps.

Auxiliary Outlets

The 12-volt receptacle can be used to power accessories, but is limited to 10 amps (the
terminal board and 12-volt outlet are fused together at 10 amps.

Mode Button

The yellow button located near the instrument cluster is used to toggle through mode options
available. See pages 24-28.

Ignition Switch/Light Switch

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

Gear Selector

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

Low gear is the primary driving range for the M1400. High gear is intended for use on hard­packed surfaces with light loads. Whenever the vehicle is left unattended, always place the
transmission in PARK.

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.

Tip: Maintaining shift linkage adjustment is important to assure proper transmission function. Your

dealer can assist in resolving any shifting problems.

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

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

OFF The engine is off. Electrical circuits are off, except Acc, 12V.
LIGHTS ON L igh ts are on. Electrical circuits are on. Electrical equipment can be used.
LIGHTS OFF Lights are off. Electrical circuits are on. Electrical equipment can be used.
START Turn the key to the START position to engage the electric starter. Turn the key

to the LIGHTS ON position after starting the engine.

21

FEATURES AND CONTROLS

Console

Gear Selector

Using Low Range

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

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

Brake Pedal

Push the brake pedal toward the floor to slow or stop
the vehicle. Apply the brakes before turning the key
on.

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.

This vehicle is equipped with a throttle release switch,
which is designed to reduce the risk of a frozen or
stuck throttle. If the throttle cable should stick in an
open position when the operator releases the throttle
pedal, engine speed will be limited, and power to the
rear wheels will be reduced.

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 37-38.

Brake Pedal Throttle Pedal

22

FEATURES AND CONTROLS

Fuel Cap

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

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

Occupant Protective
Structure (OPS)

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

No device can assure occupant protection in
the event of a rollover. Always follow all safe

operating practices outlined in this manual to
avoid vehicle rollover.

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

Extreme Use Battery

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

Fuel Cap

OPS

23

FEATURES AND CONTROLS

Seat Belts

This POLARIS vehicle is equipped with three­point lap and diagonal seat belts for the operator
and passenger. Always make sure the seat belts
are secured for all riders before operating. The
driver's seat belt is equipped with a seat belt
interlock. Vehicle speed will be limited to 15
MPH (24 km/h) if the seat belt is not secured.

The center of the seat is NOT equipped with a
seat belt. Never allow a passenger to ride between
the operator and passenger seats.

WARNING! Fa lling from a moving vehicle could result
in serious injury or death. Always fasten your seat belt
securely before operating or riding in this vehicle.

To wear the seat belt properly, follow this
procedure:

1. For 3-point belts, pull the seat belt latch downward and across your chest toward the

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

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

3. Release the strap, it will self tighten.

4. To release the seat belt, press the square red button in the buckle’s center.

Seat Belt Inspection

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

1. Push the latch plate into the buckle until it clicks. The latch plate must slide smoothly

into the buckle. A click indicates that it's securely latched.

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

3. Pull each seat belt completely out and inspect the full length for any damage, including

cuts, wear, fraying or stiffness. If any damage is found, or if the seat belt does not
operate properly, have the seat belt system checked and/or replaced by an authorized
dealer.

4. To clean dirt or debris from the seat belts, sponge the straps with mild soap and water.

Do not use bleach, dye or household detergents. Rinse the entire length of the belt
webbing. Use a garden hose to flush out the retractor and latch housings regularly.

Seat Removal

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.

Buckle

Latch Plate

24

FEATURES AND CONTROLS

Instrument Cluster

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

Speedometer

The speedometer displays
vehicle speed in either miles
per hour (MPH) or kilometers
per hour (km/h). See page 26.

Indicator Lamps

Lamp Indicates Condition

V ehi cle Speed

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

Over Tempe ratu r e Th is lamp ill uminates to indicate an overheated engine. If the

indicator flashes, the overheating condition remains, and the system
will automatically reduce engine power.

Neutral This lamp illuminates when the transmission is in neutral and the

ignition key is in the ON position.

High Beam This lamp illuminates when the headlamp switch is set to high beam.

Helmet/Seat Belt The lamp is a reminder to the operator to ensure all riders are

wearing personal protective equipment and seat belts before
operating. The driver's seat belt is equipped with a seat belt interlock.
Vehicle speed will be limited to 15 MPH (24 km/h) if the seat belt is
not secured.

Check Engine This indicator appears if an EFI-related fault occurs. Do not operate

the vehicle if this warning appears. Serious engine damage could
result. See your dealer.

Rider

Information

Center

Speedometer

Indicator

Lamps

MODE
Button

25

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

The information center is set to
display standard units of
measurement and a 12-hour clock at
the factory. To change to metric
and/or a 24-hour clock, see page 26.

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

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

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

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank.

When the last segment clears, a low fuel warning is activated. All segments including
the fuel icon will flash. Refuel immediately.

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

dealer can assist.

3. Information Display Area - This area displays odometer , trip meter, engine hour meter

and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the vehicle is operating at an

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

5. Clock - The clock displays time in a 12-hour or 24-hour format. See page 26 for

resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator that the preset service

interval has been reached. Your dealer can provide scheduled maintenance. See page 26
for resetting instructions.

7. Turf Mode Indicator (if equipped) - This indicator illuminates when the operator

unlocks the differential.

Trip 1

km

mi

RPM

FE

88

:

88

1

2

65

4

3

7

26

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

Display Units (Standard/Metric)

The display can be changed to display either standard or metric units of measurement.

Tip: To exit the set-up mode at any time, wait 10 seconds. The display automatically exits and returns

to the odometer display.

1. Turn the key to the OFF position.

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

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

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

5. Repeat the procedure to change remaining display settings.

Clock Mode

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

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

play.

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

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

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

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments. After completing the

1-minute segment, step 4 will save the new settings and exit the clock mode.

6. Turn the key to the OFF position.

Stan da r d Di splay Metric Display

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

27

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

temperature and elevation.

Programmable Service Interval

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

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

2. Press and hold the MODE button.

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

Diagnostic Display Mode

The EFI diagnostic display mode is for informational purposes only. Your dealer can provide
for all major repairs.

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

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

Inactive codes are stored in the history of the unit.

28

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

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

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

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

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

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

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

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

6. See an authorized dealer for code details and diagnosis.

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

29

OPERATION

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

Break-In Period

The break-in period for your new POLARIS M1400 is the first 25 hours of operation, or the
time it takes to use the first two tanks full of gasoline. No single action on your part is as
important as a proper break-in period. Careful treatment of a new engine will result in more
efficient performance and longer life for the engine. Perform the following procedures care­fully.

NOTICE: 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 gasoline. Heed the gasoline warnings on page 15.

2. Check the oil level. See page 55. 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 30.

6. Pull only light loads.

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

8. 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 break­in period as recommended. Pull only light loads. Avoid aggressive acceleration and high
speed operation during the break-in period.

If a belt fails, always clean any debris from the clutch air duct and from the clutch and engine
compartments when replacing the belt. See page 63.

WARNING

30

OPERATION

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

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 21, 68
Brake fluid Ensure proper level 68
Park gear Ensure vehicle does not roll when in PARK. Ensure

PARK light illuminates.

-

Front suspension Inspect, lubricate if necessary 54
Rear suspension Inspect, lubricate if necessary 54
Steering Ensure free operation 69
Tires Inspect condition and pressure 10, 70
Wheels/fasteners Inspect, ensure fastener tightness 70
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 55
Coolant level Ensure proper level 61
Coolant hoses Inspect for leaks ­Throttle Ensure proper operation 21
Air filter, pre-filter Inspect, clean 66
Headlamp Check operation, apply POLARIS dielectric grease

when lamp is replaced

72

Brake light/tail lamp Check operation, apply POLARIS dielectric grease

when lamp is replaced

73

Seat Belts Check length of belt for damage, check latches for

proper operation

23

Latches (hood/tailgate/seat) Ensure all latches are secure -

WARNING

31

OPERATION

Driving Procedure

1. All riders should wear substantial foot-

wear, long pants and a close-fitting shirt.
A hard hat or helmet and approved eye
protection are recommended when appro­priate for working or riding conditions.

2. Sit in the driver's seat.

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

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

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

6. Keeping both hands on the steering wheel, release the brake pedal and gradually push
the throttle toward the floor to begin driving.

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

8. Do not carry a passenger until you have at least two hours of driving experience with this
vehicle. Never carry more than one passenger in this vehicle. Never allow a passenger to
ride in the cargo box.

9. To stop the vehicle, release the throttle pedal completely and brake to a complete stop.

Tip: Always come to a complete stop before reversing direction.

10. Place the transmission in PARK.

11. Turn the key off.

WARNING! A rolling vehicle can cause serious injury. Remove the key when leaving the vehicle
unattended.

32

OPERATION

Driving with a Passenger

1. Perform the pre-ride inspection. See page 30.

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

3. All riders should wear substantial footwear, long pants and a close-fitting shirt. A hard
hat or helmet and approved eye protection are recommended when appropriate for
working or riding conditions.

4. Make sure all passengers secure their seat belt.

5. Do not carry more than the recommended number of passengers for your vehicle. See
page 8.

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

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

8. Vehicle handling may change with a passenger and/or cargo on board. Allow more time
and distance for braking.

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

Driving On Slippery Surfaces

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

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

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

2. Slow down before entering slippery areas.

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

4. Correct a skid by turning the steering wheel in the direction of the skid. Never apply the

brakes during a skid.

WARNING

Sideways

skid

Turn in

direction of

skid

33

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

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

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

5. Always have all passengers dismount and move away from the vehicle before operating
over an obstacle that could cause a rollover.

34

OPERATION

Driving Uphill

Whenever traveling uphill, follow these
precautions:

1. Always travel straight uphill.

2. Avoid excessively steep hills.

3. Keep both feet on the floor.

4. Always check the terrain carefully before
ascending any hill. Never climb hills with
excessively slippery or loose surfaces.

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

6. 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.

Driving Downhill

When driving downhill, follow these
precautions:

1. Avoid excessively steep hills.

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

3. Slow down.

4. Apply the brakes slightly to aid in slowing.

35

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Exercise extreme caution.

3. Avoid crossing the side of a steep hill.

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

Parking the Vehicle

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

2. When parking inside a garage or other structure, be sure that the structure is well venti-

lated and that the vehicle is not close to any source of flame or sparks, including any
appliance with pilot lights.

3. Place the transmission in PARK.

4. Turn the engine off.

5. Remove the ignition switch key to prevent unauthorized use.

36

OPERATION

Driving Through Water

Your POLARIS M1400 can operate through water up to a maximum recommended depth
equal to the floorboards.

NOTICE: Immersion can result in major damage if the vehicle isn't serviced correctly and promptly.

After immersion, always take the vehicle to your dealer service. Do not start the engine! If it's
impossible to bring the vehicle to your dealer before starting the engine, perform the service
outlined on page 65, and take the vehicle to your dealer at the first opportunity.

Follow these procedures when operating
through water:

1. Determine water depths and current before
entering water.

2. Choose a crossing where both banks have

gradual inclines.

3. Proceed slowly, avoiding rocks and

obstacles.

4. Avoid operating through deep or fast-

flowing water.

WARNING! Th e large tires on your M1400 may
cause the vehicle to float in deep or fast-flowing
water, which could result in loss of control and lead
to serious injury or death. Never cross deep or fast­flowing water with your M1400.

5. After leaving water, always dry the brakes by applying light pressure to the pedal repeat-

edly until braking action is normal.

NOTICE: After running your vehicle in water, it's critical that you perform the services outlined in the

Periodic Maintenance Chart beginning on page 51. Give special attention to engine oil,
transmission oil, front and rear gearcases (if equipped), and all grease fittings.

Parking on an Incline

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

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Block the rear wheels on the downhill side.

Floorboard

37

OPERATION

Hauling Cargo

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:

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

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. Reduce speed and avoid

abrupt turns when carrying loads that extend over the side of the box.
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 backi ng downhill.

USE EXTREME CAUTION when operating with loads that extend over the box sides. Stability and
maneuverability may be adversely affected, causing a rollover.

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

The POLARIS M1400 has been designed to carry or tow specific capacities. Always read
and understand the load distribution warnings listed on the warning labels.

The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed
the maximum weight capacity of the vehicle. Never exceed the following capacities.

WARNING! Driving with passengers in the cargo
box can result in severe injury or death. Never allow
passengers to ride in the cargo box.

Model Maximum Capacities

(Level Ground)

Cargo Box

POLARIS M1400 1450 lbs. (658 kg) 1100 lbs. (499 kg)

WARNING

38

OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or brake
instability. Always follow these precautions when towing:

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

2. Do not operate the vehicle faster than 10 MPH (16 km/h) when towing. See page 37.

Towing a trailer increases braking distance.

3. Do not tow more than the recommended weight for the vehicle. See the towing capacity

chart below and the specifications charts beginning on page 82.

4. Attach a trailer to the trailer hitch bracket only. Do not attach a trailer to any other

location or you may lose control of the vehicle.

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

Belt Life

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

Towing the Vehicle

Follow these procedures when towing the vehicle:

1. Place the gear selector in neutral.

2. Turn the key off.

3. Always follow these precautions when towing this vehicle:

• Do not operate faster than 10 MPH (16 km/h).

• Do not tow on public streets.

• Do not allow passengers in the towed vehicle.

• Avoid abrupt starts and stops.

• Avoid sharp turns and abrupt steering maneuvers.

• Avoid towing on a hill.

Model Total Towed

Load Weight

(Level Ground)

Tot al Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

POLARIS M1400 1500 lbs.

(680.4 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 MPH
(16 kph)

39

OPERATION

Dumping the Cargo Box

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

2. Apply the brakes.

3. Place the transmission in PARK.

4. Dismount the vehicle.

5. Ensure that the cargo is positioned evenly or toward the front

of the cargo box.

WARNING! If the weight distribution on the box is located toward the rear
of the box when using the release lever, the box may dump unexpectedly
when the lever is pulled 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.

6. Release the tailgate latches and lower the tailgate.

7. Using Electric Switch: Press and hold the top of the dump box

switch to dump the cargo. Release the switch after the cargo
has dumped or when the box reaches the fully elevated
position, indicated by a ratcheting sound. Press and hold the
bottom of the dump box switch to lower the cargo box.
Release the switch when the box is fully seated on the frame,
indicated by a ratcheting sound.
Using Release Lever: Stand clear of the cargo box and pull
the release lever. Lift the front of the cargo box to dump the
cargo. Lower the cargo box and push down securely to latch.
Make sure the box is fully seated on the frame before
operating the vehicle.

8. Close the tailgate and secure both tailgate latches.

WARNING! Op erating 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.

Release

Lever

Dump Box Switch

40

OPERATION

Transporting the Vehicle

When transporting the POLARIS M1400 for a long distance or on public streets, always use
a trailer with an approved load rating greater than the POLARIS M1400 curb vehicle weight
of 1060 lbs. (481 kg) plus any installed accessories or cargo.

Follow these guidelines when transporting the POLARIS M1400.

1. Place the transmission in PARK.

2. Remove the key to prevent loss.

3. Secure the seat, hood and tailgate latches. Ensure that the seats are attached correctly and
are not loose.

WARNING! Cargo and other loo se vehicle parts may fly off while transporting this vehicle. Secure or
remove all cargo, and inspect the unit for loose parts prior to transport.

4. Always tie the frame of the vehicle to the transporting unit securely with suitable straps.

5. If using an open trailer, remove the windshield (if equipped).

6. Never allow passengers on a trailer or in a trailered vehicle.

7. Reduce speed and drive with caution.

41

WINCH GUIDE

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

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

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

Winch Safety Precautions

1. Read all sections of this manual.

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

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

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

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

6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the
Shock Loading section on page 48.

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

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

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

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

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

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

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

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

B. If stacking occurs, stop winching. Follow step 15 on page 46 to feed and rewind the cable

evenly before continuing the winch operation.

WARNING

42

WINCH GUIDE

Winch Safety Precautions

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

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

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

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

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

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

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

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

21. Never immerse or submerse your winch in water. Your dealer can provide service on
your winch if this occurs.

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

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

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

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

43

WINCH GUIDE

Winch Operation

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

Tip: Consider practicing the operation and use of your winch before you actually need to use it in the

field.

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

Each winching situation is unique.

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

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

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

• Always remember that your winch is very powerful.

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

1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of
damage or parts in need of repair or replacement before each use. Pay particular

attention to the first 3 feet (1 meter) of winch cable if the winch is being used (or has
been used) for lifting an accessory plow assembly. Promptly replace any worn or

damaged cable.

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

3. Always apply your vehicle’s park brake and/or

park mechanism to hold the vehicle in place
during winching. Use wheel chocks if needed.

WARNING

Hook Strap

44

WINCH GUIDE

Winch Operation

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

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

A. Attach the hook itself onto the load or use a tow strap or

chain to secure the load to the winch cable.

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

is designed to stretch.

WARNING! Never use a recove ry strap when winching due to
the excessive energy that can be released if the winch cable breaks. This can result in SEVERE
INJURY or DEATH. See the Shock Loading section on page 48.

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

in winch cable failure.

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

C. If possible, keep the winch cable aligned with the centerline of the winching vehicle. This will

help the spooling of the winch cable and reduce the load on the fairlead.

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

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

E. Before operating the winch, be sure that the safety latch on

the winch cable hook is fully seated when the load is
attached.

F. Never operate your winch with a damaged hook or latch.

Always replace damaged parts before using the winch.

5. Never remove the hook strap from the hook.

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

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

NO YES

NO

YES

45

WINCH GUIDE

Winch Operation

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

A. In order to absorb energy that could be released by a winch cable failure, always place a

“damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense
object. A damper can absorb much of the energy released if a winch cable breaks when

winching. Even a tree limb can help as a damper if no other items are available to you.
B. Lay the damper on top of the mid-point of the winch cable le ngth that is spooled out.
C. On a long pull, it may be necessary to stop winching so that the damper can be repositioned

to the new mid-point of the winch cable. Always release the tension on the winch cable before

repositioning the damper.
D. Avoid being directly in line with the winch cable whenever possible. Also, never permit others

to stand near or in line with the winch cable during winch operation.

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

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

11. The ONLY time a winch-equipped vehicle should be moving when using the winch is
when that vehicle itself is stuck. The winch-equipped vehicle should NEVER be in
motion to “shock” load the winch cable in an attempt to move a second stuck vehicle.
See the Shock Loading section on page 48. For your safety, always follow these
guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch cable.
B. Align the winch cable as close as possible to the winching vehicle’s centerline.
C. Attach the winch cable hook to the anchor point or the stuck vehicle’s frame following

instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the dire ction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself without the help of the

winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the instructions in this

manual.

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

46

WINCH GUIDE

Winch Operation

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

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

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

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

hook strap.

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

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

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

winch cable.

47

WINCH GUIDE

Winch Cable Care

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

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

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

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

cable.

A. A kinked winch cable made of wire rope is shown at

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

B. A kinked winch cable made of wire rope tha t ha s been

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

C. A winch cable made of synthetic rope should be

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

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

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

A

B

C

48

WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic, or “shock” loading.

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

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

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

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

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

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

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

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

4. Never use recovery straps with your winch. Recovery straps are designed to stretch and

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

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

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

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

49

WINCH GUIDE

Winch Maintenance and Service Safety

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

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

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

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

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

accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including the cable) with

genuine POLARIS replacement parts available at your authorized dealer.

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

designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade polymer rope such as

can be purchased in a hardware store. Although they may look similar, they are NOT
alike. A polymer rope not designed for winch use will stretch and store excessive energy
when winching.

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

50

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance
with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level require­ments.

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

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

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located on the

front side of the metal seatbase.

Electromagnetic Interference

This spark ignition system complies with Canadian
ICES-002.

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

Non-ionizing Radiation: This vehicle emits some electromagnetic energy . People with active
or non-active implantable medical devices (such as heart monitoring or controlling devices)
should review the limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.

Emissions Label

(front side of metal seatbase)

51

MAINTENANCE

Periodic Maintenance Chart

Any qualified repair shop or person may maintain, replace or repair the emission control
devices or systems on your vehicle. An authorized POLARIS dealer can perform any service
that may be necessary for your vehicle. POLARIS also recommends POLARIS parts for
emissions-related service, however equivalent parts can be used.

It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering with
emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in this owner’s
manual.

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, genuine POLARIS parts are available from your POLARIS
dealer. Equivalent parts may be used for emissions-related service.

Record maintenance and service in the Maintenance Log beginning on page 93.

Tip: Service and adjustments are important for proper vehicle operation. If you're not familiar with safe

service and adjustment procedures, a qualified dealer can perform these operations.

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

Maintenance Chart Key

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

D Have an authorized dealer or other qualified person perform these services.

WARNING! Improperly performing the procedures marked with a “D” could result in component failure

and lead to serious injury or death. Have an authorized dealer or other qualified person perform these
services.

52

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first. Check and lubricate
all components at the intervals outlined in the Periodic Maintenance Chart, 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.

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

D Have an authorized dealer or other qualified person perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering -

Pre-Ride

-

Inspect and make adjustments as

needed. See Pre-Ride Checklist on

page 30.

Front suspension - ­Rear suspension - ­Tires - ­Brake fluid level - ­Brake pedal travel
Brake system - ­Wheels/fasteners - ­Frame fasteners - ­Batteries - ­Engine oil level ­Headlamp/tail lamp - Daily - Check operation; apply dielectric

grease if replacing

Ź Air filter, pre-filter - Daily - Inspect; clean often; replace as needed

Coolant - Daily - Check level

Ź Air filter - Weekly - Inspect; replace as needed

Fuel System 25 H Monthly - Inspect; cycle key to pressurize fuel

pump; check lines and fittings for leaks
and abrasion

Ź Front Gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check
Ź Middle Gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check
Ź Rear gearcase oil (if equipped) 25 H 1 M - Perform a break-in oil level check
Ź Transmission oil 25 H 1 M 250 (400) Perform a break-in oil level check
Ź Engine oil change (break-in) 25 H 1 M - Perform a break-in oil change at one

month

Ź

D

Brake pad wear 50 H Monthly - Inspect periodically

Ź General lubrication 50 H 3 M - Lubricate all fittings, pivots, cables, etc.

D Steering 50 H 6 M - Lubricate

Ź Front suspension 50 H 6 M - Lubricate
Ź Rear suspension 50 H 6 M - Lubricate

D Throttle cable/Release switch 50 H 6 M 500 (800) Inspect; adjust; lubricate; replace if

necessary

Throttle body air intake ducts/
flange

50 H 6 M 500 (800) Inspect duct for proper sealing/air leaks

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

53

MAINTENANCE

Periodic Maintenance Chart

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

D Have an authorized dealer or other qualified person perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

Cooling system (if applicable) 50 H 6 M - Inspect coolant strength seasonally;

pressure test system yearly

Ź Oil lines, fasteners 50 H 6 M - Inspect for leaks and loose fittings
Ź Wiring 100 H 12 M - Inspect for wear, routing, security; apply

dielectric grease to connectors
subjected to water, mud, etc.

D Front wheel bearings 100 H 12 M - Inspect; replace as needed
D Fuel system 100 H 12 M 1000 (1600) Cycle key to pressurize fuel pump;

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

D Toe adjustment - Inspect periodically; adjust when parts

are replaced

D Headlight aim - Adjust as needed

Ź Engine oil and filter change 100 H 6 M 1000 (1600) Change oil and filter; (perform a break-

in oil change at one month)

Ź Front Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly
Ź Middle Gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly
Ź Rear gearcase oil (if equipped) 100 H 6 M - Inspect level; change yearly
Ź Transmission oil 100 H 12 M 1000 (1600) Change fluid

D Fuel system 100 H 12 M 1000 (1600) Check for leaks at tank cap, lines,

pump, throttle body; replace lines every
2 years

Ź Radiator (if applicable) 100 H 12 M - Inspect; clean external surfaces
Ź Cooling Hoses 100 H 12 M - Inspect for leaks
Ź Engine mounts 100 H 12 M - Inspect

Exhaust muffler/pipe 100 H 12 M - Inspect

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

D Ignition timing 100 H 12 M - Inspect

Ź Wiring 100 H 12 M - Inspect for wear, routing, security; apply

dielectric grease to connectors sub­jected to water, mud, etc.

DŹClutches 100 H 12 M 1000 (1600) Inspect; clean; replace worn parts
D Front wheel bearings 100 H 12 M - Inspect; replace as needed

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

Spark arrester 300 H 36 M - Clean out

Ź Coolant - 60 M - Replace coolant

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

D Toe adjustment - Inspect periodically; adjust when parts

are replaced

DŹAuxiliary brake (if equipped) - Inspect daily; adjust as needed

Headlight aim - Adjust as needed

54

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Periodic Maintenance
Chart beginning on page 51, or more often under severe use, such as wet or dusty conditions.
Items not listed in the chart should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 5W-50 4-Cycle Oil See page 55.
Brake Fluid DOT 4 Brake Fluid See page 68.
Main Gearcase Oil (Transmission) AGL Gearcase Lubricant & Transmission

Fluid

See page 58.

Front Gearcase Oil (if equipped) Demand Drive Fluid See page 59.
Front Prop Shaft Yoke (if equipped) U-Joint Grease Locate fittings and grease (3

pumps maximum).

55

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals
outlined in the Periodic Maintenance Chart beginning on
page 51. Always use the recommended engine oil. See
page 54.

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

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

Oil Check

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

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Always clean away all dirt and debris from the

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

4. Reinstall and tighten the dipstick.

5. Remove the dipstick and check the oil level.

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

6. Add the recommended fluid as needed.

7. Reinstall and tighten the dipstick.

Oil Dipstick (Check/Fill)

Upper Oil Fill

Full

Add

56

MAINTENANCE

Engine Oil

Oil and Filter Change

Always check and change the oil at the intervals outlined in the Periodic Maintenance Chart
beginning on page 51. Always change the oil filter whenever changing oil.

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

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

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

3. Clean the area around the drain plug.

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

4. Place a drain pan beneath engine crankcase and

remove the drain plug.

5. Allow the oil to drain completely.

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

Tip: The sealing surfaces on drain plug and crankcase

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

7. Reinstall the drain plug. Torque to 11-13 ft. lbs.

(14.5-17.5 Nm).

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

on the crankcase.

9. Place shop towels beneath the filter cover to catch

oil drips. Remove the cover screws and remove
the cover to access the oil filter.

10. Remove the oil filter and spring, retaining the

spring for reinstallation.

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

crankcase.

Spring

Filter

Sealing
Washer

Drain

Plug

O-Ring

Filter Cover

57

MAINTENANCE

Engine Oil

Oil and Filter Change

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

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

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

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

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

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

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

19. Stop the engine. Inspect for leaks.

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

21. Dispose of used filter and oil properly.

58

MAINTENANCE

Gearcases

Gearcase Specification Chart

Transmission (Main Gearcase)

Always check and change the transmission oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 51. Maintain the oil level even with the bottom thread
of the fill plug hole.

Refer to the Gearcase Specifications Chart for recommended lubricants, capacities and
torque specifications. See page 84 for the part numbers of POLARIS products.

Fluid Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

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

5. Reinstall the fill plug. Torque to specification.

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

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

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

Gearcase Lubricant Capacity Fill Plug(s)

Torque

Drain Plug

Torque

Main Gearcase
(Transmission)

AGL Gearcase

Lubricant &

Transmission Fluid

44 oz.

(1300 ml)

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

Front Gearcase
(if equipped)

Demand Drive Fluid 9.3 oz.

(275 ml)

8-10 ft. lbs.

(11-13.6 Nm)

11 ft. lbs.

(15 Nm)

Fill Plug

View from

rear of vehicle

View from rear left

side of vehicle

Drain Plug

59

MAINTENANCE

Gearcases

Front Gearcase (if equipped)

Always check and change the front gearcase oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 51. Maintain the oil level even with the bottom thread
of the fill plug hole.

Refer to the Gearcase Specifications Chart on page 58 for recommended lubricants, capaci­ties and torque specifications. See page 84 for the part numbers of POLARIS products.

Oil Check

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

1. Position the vehicle on a level surface.

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

3. Add the 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.

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

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

8. Reinstall the fill plug. Torque to specification.

9. Check for leaks.

10. Discard used oil properly.

Drain Plug

Fill Plug

60

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 82 for the recommended spark plug
type for your vehicle. Always torque spark plugs to specification.

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

POLARIS-recommended spark plugs or their equivalent.

Spark Plug Gap/Torque

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.

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

1. Lift the cargo box to access the spark plugs.

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

3. Reverse the procedure for spark plug installation.

4. Torque to specification.

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.

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 or incorrect throttle body adjustments.

Model Electrode Gap New or Used Plug

Torque

POLARIS M1400 .031” (.7-.9 mm) 9 ft. lbs. (12 Nm)

61

MAINTENANCE

Cooling System

The engine coolant level is controlled or maintained by the recovery system. The recovery
system components are the overflow bottle, radiator filler neck, radiator pressure cap and
connecting hose.

As coolant operating temperature increases, the expanding (heated) 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.

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

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This antifreeze is
already premixed and ready to use. Do not dilute with water. See page 84 for the part
numbers of POLARIS products.

To ensure that the coolant maintains its ability to protect the engine, we recommend that the
system be completely drained every five (5) years and fresh Antifreeze 50/50 Premix added.

Any time the cooling system has been drained for maintenance or repair, replace the coolant
with fresh Antifreeze 50/50 Premix. If the recovery bottle has run dry, the level in the
radiator should be inspected. Add coolant as needed.

Radiator and Cooling Fan

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic
Maintenance Chart beginning on page 51. Do not obstruct or deflect air flow through the
radiator by installing unauthorized accessories in front of the radiator or behind the cooling
fan. Interference with the radiator air flow can lead to overheating and consequent engine
damage.

NOTICE: Washing the vehicle with a high-pressure hose could damage the radiator fins and impair

the radiator's effectiveness. Using a high-pressure system is not recommended.

62

MAINTENANCE

Cooling System

Overflow Bottle Coolant Level

Always check and change the coolant at the intervals
outlined in the Periodic Maintenance Chart beginning
on page 51. Maintain the coolant level between the
minimum and maximum marks on the bottle (when the
fluid is cool).

1. Position the vehicle on a level surface.

2. Lift the hood. View the coolant level in the
overflow bottle.

3. If the coolant level is below the safe operating
range, lift the hood and locate the overflow bottle
lid. Remove the cap and use a funnel to add coolant
through the filler opening. Reinstall the cap.

Tip: If coolant must be added often, or if the overflow bottle

runs completely dry, there may be a leak in the system.
Your dealer can inspect the cooling system.

Radiator Coolant Level

Always check and clean the screen and radiator fins at the intervals outlined in the Periodic
Maintenance Chart beginning on page 51. 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 consequentially,
engine damage.

1. Lift the hood.

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

2. Slowly remove the radiator cap.

3. View the coolant level through the opening.

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

Tip: This procedure is required only if the cooling system has been drained for maintenance and/or

repair. But if the overflow bottle has run dry, the level in the radiator should also be inspected.

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

Radiator

Cap

Overflow

Bottle Cap

63

MAINTENANCE

POLARIS Variable Transmission (PVT) System

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. As the
owner, you have the following responsibilities for your own safety and the safety of others:

• Always follow all recommended maintenance procedures. Always look for and remove debris inside
and around the clutch and vent system when replacing the belt.

• See your dealer 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 pl ace during operation.

Belt Replacement/Debris Removal

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

WARNING! Failure to remove ALL debris when replacing the belt could result in vehicle damage, loss
of control and severe injury or death.

1. Position the vehicle on a level surface. Block the

wheels to prevent vehicle movement. Place the
transmission in neutral.

2. Lift the cargo box.

3. Remove the clutch cover screws using a 3/8”

socket with ratcheting wrench and extension.

4. Pull the bottom of the cover outward and over

the suspension to remove it.

5. Make sure the cover gasket does not fall out of the groove when removing the cover.

6. Squeeze the belt together so that it submarines further into the driven clutch, creating

slack in the belt between the clutches.

7. Remove the belt by using the slack to pull part of the belt off the driven clutch.

WARNING

Step 3

Step 5 Step 6

Step 7

64

MAINTENANCE

POLARIS Variable Transmission (PVT) System

Belt Replacement/Debris Removal

8. Rotate the driven clutch by hand until the belt is completely off.

9. Slide the front of the belt out from between the
drive clutch and inner clutch cover to completely
remove it.

10. Remove all debris wrapped in and around the
PVT system.

11. Remove all debris from the entire clutch air duct
passage.

12. Check for signs of damage to seals on the
transmission and engine. See your dealer
promptly for service if any seals appear to be
damaged.

Tip: 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.).

13. To install a belt, place one end of the belt over the
driving clutch. Route the belt over the top of the
driven clutch and down into the groove of the
clutch to allow slack in the belt. Rotate the driven
clutch by hand until the belt falls into place.

14. Reinstall the clutch cover in the reverse order of
removal, fitting the top of the cover into place,
then working the bottom of the cover over the
suspension.

15. Install all clutch cover screws. Torque to 4-5 ft.
lbs. (5.5-6.5 Nm).

Step 8

Step 9

Remove ALL Debris

65

MAINTENANCE

POLARIS Variable Transmission (PVT) System

PVT Drying

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

1. Position the vehicle on a level surface.

2. Allow the water to drain completely.

3. Place the transmission in PARK.

4. Start the engine.

5. 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 five (5) seconds.

6. Allow the engine RPM to settle to idle speed.
Apply the brakes. Shift the transmission to the
lowest available range.

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

8. Take the vehicle to your dealer for service as soon as possible. Your dealer can assist.

Vehicle Immersion

NOTICE: If your vehicle becomes immersed, major engine damage can result if the machine is not

thoroughly inspected. Take the vehicle to your dealer before starting the engine.

If it's impossible to take your vehicle to a dealer before starting it, follow the steps outlined
below.

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

2. Dry any water present in the air box. Filter replacement is required if water is present.

3. Remove the spark plugs. Turn the engine over several times using the electric start.

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

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

6. Take the vehicle in for service as soon as possible, whether you succeed in starting it or
not. Your POLARIS dealer can provide the required service.

7. If water has been ingested into the PVT follow the procedure on page 65 for drying.

Drain

66

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the intervals
outlined in the Periodic Maintenance Chart
beginning on page 51.

1. Lift the cargo box.

2. Clean all dirt and debris from the air box area.

3. Unlatch the two (2) cover clips and carefully
remove the air box cover. Inspect the seal
between the cover and air box to ensure the
seal is not torn and has been maintaining a
proper seal.

4. Inspect the air filter and air box for dirt,
debris, oil or water. If the filter needs to be
replaced, remove the worm gear clamp from
the filter neck with a flat-blade screwdriver or 6mm socket. Slide the filter rearward to
remove it from the boot, then lift it straight upward and out of the air box.

5. With the filter removed, clean the intake boot and air box thoroughly and wipe well with
a clean, dry cloth.

NOTICE: Dirt or debris in the intake boot could result in severe engine damage. Always clean all dirt

and debris from the intake boot before installing the filter.

6. Reinstall the air filter (if clean) or install a new air filter (if soiled). Do not attempt to
clean the air filter.

NOTICE: Use of a non-POLARIS-approved air filter may cause engine damage. Always use a

POLARIS-approved replacement filter. See page 84 for the part numbers of POLARIS
products.

7. Make sure the filter is fully seated on the intake boot and that there is no gap between the
filter and boot after installation. Tighten the worm gear clamp to 24 in. lbs. (2.7 Nm).

8. Reinstall the air box cover. Make sure both hinges are fully inserted. Secure the cover
clips.

Cover Clips

View of Under-Box Area

67

MAINTENANCE

Spark Arrester

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

• Do not perform service on the spark arrester 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 operate without the spark arrester.

• 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 arrester clean-out plug located on the bottom of the muffler.

2. Place the transmission in PARK.

3. Start the engine.

4. Purge accumulated carbon from the system by momentarily revving the engine several

times.

5. If carbon is expelled, cover or plug the exhaust outlet and rap on the pipe around the

clean-out plug while revving the engine several more times.

6. If particles are still suspected to be in the muffler , elevate the rear of the vehicle one foot

higher than the front. Block the wheels.

7. Repeat steps 4 and 5 until no more particles are expelled when the engine is revved.

8. Stop the engine. Allow the arrester to cool.

9. Reinstall the arrester plug and remove the outlet cover or plug.

WARNING

68

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc type brakes. Press down on the brake pedal to
engage the brakes. See page 21.

Brake Fluid

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

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.

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. Use only DOT 4 brake fluid.

1. Position the vehicle on a level surface.

2. View the brake fluid level at the reservoir in the
driver’s side wheel well. 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.

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. Check brake discs for signs of cracks, excessive
corrosion, warping or other damage. Clean any grease
using an approved brake cleaner or alcohol.

WARNING! Do not apply WD-40 or any petroleum product to
brake discs. These types of products are flammable and may
also reduce the friction between the brake pad and caliper.

5. Inspect the brake disc spline and pad wear surface for
excessive wear. Change pads when worn to 0.030" (0.762 mm).

Maximum

Minimum

0.030" (0.762 mm)

69

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 51.

1. Position the vehicle on a level surface.

2. Lightly turn the steering wheel left and right. There should be 0.8"-1.0” (20-25 mm) of
freeplay at the outer rim of the steering wheel.

3. If there is excessive freeplay or strange noises, or the steering feels rough or “catchy,”
have the steering system inspected by an authorized dealer.

Spring Adjustment

Adjust the rear shock absorber springs by rotating the adjustment cams
either clockwise or counter-clockwise to increase or decrease spring
tension.

Cam

70

MAINTENANCE

Tires

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

Tire Tread Depth

Always replace tires 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. Do not lubricate the stud or the lug nut.

Wheel Removal

1. Apply the brakes. Place the transmission in PARK. Turn the key off.

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.

Nut Type Location Nut Torque

Wheel Nut Front and Rear 65 ft. lbs. (88 Nm)
Spindle Nut Front 75 ft. lbs. (102 Nm)
Hub Retaining Nuts Rear 110 ft. lbs. (150 Nm)

WARNING

1/8" (3 mm)

71

MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in PARK. 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.

WARNING! Imp roperly installed whe els 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.
Your dealer can assist.

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

3. Carefully lower the vehicle to the ground.

4. Torque the wheel nuts to specification.

Fuses

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

The fuse box is located in the electrical
compartment under the left rearmost seat. Spare
fuses are provided in the fuse box.

If you suspect that a fuse or relay may not be
working properly, please see your dealer.

Fuse Size Feature Supported

5A Brake Light
10A Drive System, Fuel Pump
20A EFI, Power Steering (if equipped),

Lights, Accessories

20A Circuit

Breaker

Fan

72

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight and taillight lenses
become dirty during normal operation. Clean lights frequently and replace burned out lamps
promptly. Do not operate this vehicle at night or in low light conditions until the headlight is
replaced. Always make sure lights are adjusted properly for best visibility.

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.

Headlight Lamp Replacement

1. Open the hood.

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

2. Unplug the headlamp from the wiring harness.
Be sure to pull on the connector, not on the
wiring.

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

4. Install the new lamp.

Tip: Make sure the tab on the lamp locates properly in the

housing.

5. Reinstall the harness assembly into the headlight
assembly.

Wiring Harness

73

MAINTENANCE

Lights

Headlight Beam Adjustment

1. Place the vehicle on a
level surface with the
headlight approximately
25 ft. (7.6 m) from a
wall.

2. Measure the distance

from the floor to the
center of the headlight
and make a mark on the
wall at the same height.

3. Apply the brakes. Turn

the key on. Turn the
headlights on.

4. Observe the headlight aim. The most intense part of the headlight beam should be aimed

8" (20 cm) below the mark placed on the wall. Include the weight of a rider on the seat
while performing this step.

5. If a headlight needs adjustment, access the adjustment screw under the hood or through

the wheel well.

6. Loosen the screw, adjust the headlight, and tighten the screw.

7. Repeat steps 4-6 until the lamp is properly adjusted.

Brake Lights

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

1. Turn the key to the ON position.

2. Apply the brakes. If the light doesn't come on, check the wiring, the brake switch or the

taillight assembly.

25 ft.

(7.6 m)

8" (20 cm)

XX

74

MAINTENANCE

Battery

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.

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.

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.

Battery Fluid (Conventional Battery)

A poorly maintained battery will deteriorate rapidly. Check
the battery fluid level often. Maintain the fluid level between
the upper and lower level marks.

Add only distilled water . Tap water contains minerals that are
harmful to a battery.

WARNING

Lower

Mark

Upper

Mark

75

MAINTENANCE

Battery

Battery Removal

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.

1. Remove the seat to access the battery compartment.

2. On conventional batteries, remove the battery vent

tube.

3. Disconnect the black (-) battery cable first.

Disconnect the red (+) battery cable last.

4. Remove the battery hold-down strap.

5. Lift the battery out of the vehicle. Be careful not to tip

a conventional battery sideways, which could spill
electrolyte.

NOTICE: 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.

WARNING

76

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 77 before installing the battery.

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

1. Ensure that the battery is fully charged.

2. Place the fully charged battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed batteries do not have a
vent tube). The vent tube must be free of obstructions and securely installed. Route the
tube away from the frame and vehicle body to prevent contact with electrolyte.

WARNING! Batte ry 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. Coat the terminals with dielectric grease or petroleum jelly.

5. Connect and tighten the red (+) cable first. Connect and tighten the black (-) cable last.

6. Verify that cables are properly routed. Cables should be safely tucked away at the front
and rear of the battery.

7. Install the battery hold-down strap.

Battery Storage

Whenever the vehicle is not used for a period of three months or more, remove the battery
from the vehicle, ensure that it's fully charged, an d store it out of the sun in a cool, dry place.
Check battery voltage each month during storage and recharge as needed to maintain a full
charge. See page 77.

POLARIS recommends maintaining battery charge by using a POLARIS Battery Tender
charger or by charging about once a month to make up for normal self-discharge. Battery
Tender can be left connected during the storage period, and will automatically charge the
battery if the voltage drops below a pre-determined point. See page 84 for the part numbers
of POLARIS products.

77

MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leaking or spilled
electrolyte during charging. See page 75.

2. Charge the battery with a charging output no larger than 1/10 of the battery’s amp/hr

rating. Charge as needed to raise the specific gravity to 1.270 or greater.

3. Reinstall the battery. See page 76. Make sure the positive terminal is toward the driver’s

side of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installation of a sealed battery.
Read all instructions before proceeding with the installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed and fully charged at
the factory. Never pry the sealing strip off or add any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to keep it fully
charged. Since the battery is sealed and the sealing strip cannot be removed, you must use a
voltmeter or multimeter to measure DC voltage.

WARNING! An overheated battery may explode, causing severe injury or death. Always watch
charging times carefully. Stop charging if the battery becomes very warm to the touch. Allow it to cool
before resuming charging.

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will
register 12.8 V or higher . If the voltage is less than 12.8 volts, recharge the battery at 1.2
amps or less until battery voltage is 12.8 or greater.

2. When using an automatic charger, refer to the charger manufacturer's instructions for

recharging. When using a constant current charger, use the guidelines below for
recharging.

Always verify battery condition before and 1-2 hours after the end of charging.

Stat e of

Charge

Voltage Action

Charge Time

(Using constant current

charger @ standard amps

specified on top of battery)

100% 12.8-13.0 volts None, check at 3 mos. from date of

manufacture

None required

75%-100% 12.5-12.8 volts May need slight charge, if no charge

given, check in 3 months

3-6 hours

50%-75% 12.0-12.5 volts Needs charge 5-11 hours
25%-50% 11.5-12.0 volts Needs charge At least 13 hours,

verify state of charge

0%-25% 11.5 volts or less Needs charge with desulfating charger At least 20 hours

78

MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your POLARIS vehicle clean will not only improve its appearance but it can also
extend the life of various components.

NOTICE: High water pressure may damage components. POLARIS recommends washing the vehicle

by hand or with a garden hose, using mild soap.

NOTICE: Certain products, including insect repellents and chemicals, will damage plastic surfaces.

Do not allow these types of products to contact the vehicle.

The best and safest way to clean your POLARIS vehicle is with a garden hose and a pail of
mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first and the lower parts
last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and

pads may contain dirt particles that will scratch the finish.

• Avoid directing water toward electrical components, including batteries, wiring and

switches.

If a high pressure water system is used for cleaning (not recommended), exercise extreme
caution. The water may damage components and could remove paint and labels. Avoid
directing the water stream at the following items:

• Wheel bearings

• Transmission seals

•Brakes

• Radiator

• Cab and body panels

• Labels and decals

• Switches and controls

• Electrical components and wiring

If an informational or graphic label becomes illegible or comes off, contact your dealer to
purchase a replacement. Replacement safety labels are provided at no charge.

Grease all zerk fittings immediately after washing.

79

MAINTENANCE

Cleaning and Storage

Polishing the Vehicle

POLARIS recommends the use of common household aerosol furniture polish for polishing
the finish on your POLARIS vehicle. Follow the instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the finish of your
vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or reused cloths and
pads may contain dirt particles that will scratch the finish.

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the protective film created by

fogging and damage could occur. Never start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and clean the vehicle as recommended. See page 78.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel S tabilizer or equivalent

fuel treatments or stabilizers. Follow the instructions on the container for the recom­mended amount. Carbon Clean removes water from fuel systems, stabilizes fuel and
removes carbon deposits from pistons, rings, valves and exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to disperse through the

entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 55.

Air Filter / Air Box

1. Inspect and clean or replace the pre-cleaner and air filter. See page 66.

2. Clean the air box.

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic
Maintenance Chart beginning on page 51.

80

MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the fluid levels. Add or change fluids as recommended in the Periodic Maintenance
Chart beginning on page 51.

• Front and rear gearcase fluid (if equipped)

• Transmission fluid

• Brake fluid (change every two years and any time the fluid looks dark or contaminated)

• Coolant (test strength/fill)

Fog the Engine

1. Treat the fuel system with POLARIS Carbon Clean or other equivalent fuel treatment.
Follow the instructions on the container. Start the engine. Allow it to idle for several
minutes so the Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of engine oil. To access the plug holes,

use a section of clear 1/4” hose and a small plastic squeeze bottle filled with the pre­measured amount of oil. Do this car efully! If you miss the plug holes, oil will drain from
the spark plug cavities into the hole at the front of the cylinder head, and appear to be an
oil leak.

3. Reinstall the spark plugs. Torque to specification. See page 60.

4. Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto

the plugs.

5. Turn the engine over several times. Oil will be forced in and around the piston rings and

ring lands, coating the cylinder with a protective film of fresh oil.

6. If POLARIS fuel system additive is not used, fuel tank, fuel lines, and injectors should

be completely drained of gasoline.

Storage Area/Covers

Be sure the storage area is well ventilated. Cover the vehicle with a genuine POLARIS
cover. Do not use plastic or coated materials. They do not allow enough ventilation to pre­vent condensation, and may promote corrosion and oxidation.

81

MAINTENANCE

Storing the Vehicle

Any time the vehicle will be parked for more than a few hours, follow the recommended
storage procedures:

1. Make any necessary repairs and clean the vehicle. See page 78.

2. Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic
Maintenance Chart beginning on page 51.

3. Perform battery maintenance. Clean the batteries. See pages 74-77.

4. Inspect the fluid levels. Add or change fluids as recommended in the Periodic
Maintenance Chart beginning on page 51.

5. Store the vehicle out of the sun in a cool, dry place.

6. Be sure the storage area is well ventilated.

Tip: Do not use plastic or coated materials to cover the vehicle. They do not allow enough ventilation to

prevent condensation, and may promote corrosion and oxidation.

7. Turn the key off.

8. Verify that tire pressure is at specification.

9. Block the wheels to prevent rolling.

10. Fully charge the batteries. Leave the charger connected to maintain a full charge during
the storage period, or check battery voltage each month during storage and recharge as
needed to maintain a full charge. If the charger remains connected, check it monthly to
verify proper operation.

WARNING! Do not cover th e vehicle while the charger is connected. Dangerous levels of hydrogen
gas could accumulate.

Removal from Storage

1. Inspect all battery connections.

2. Verify that batteries are fully charged.

3. Make sure the spark plug is tight.

4. Fill the fuel tank with fuel.

5. Verify that tire pressure is at specification.

6. Perform the pre-ride inspection. See page 30.

7. Inspect and verify the tightness of the bolts, nuts and other fasteners.

8. Lubricate at the intervals outlined in the Periodic Maintenance Chart beginning on page

51.

82

SPECIFICATIONS

POLARIS M1400

Dimensions

Maximum Weight Capacity
(includes weight of operator, pas­senger, cargo, accessories)

1450 lbs. (658 kg)

Dry Weight 1060 lbs. (481 kg)
Ground Clearance 8.5 in. (21.6 cm)
Length 114.5 in. (291 cm)
Width 56.5 in. (143.5 cm)
Height 73 in. (185.4 cm)
Cargo Box (Inside) 51.5 x 41.75 in. (130.8 x 106 cm)
Wheelbase 79 in. (200.7 cm)
Turning Radius (GVW) Left: 175 in. (444.5 cm)

Right: 159 in. (403.9 cm)

Turning Radius (LVW) Left: 176.2 in. (447.5 cm)

Right: 158.6 in. (402.8 cm)
Fuel Capacity 8.8 gal. (33.3 l)
Engine Oil Capacity 1.75 qts. (1.6 l)
Coolant Capacity 120 oz. (3.5 l)

Load Capacity

Cargo Box Capacity 1100 lbs. (499 kg)
Payload Capacity 1450 lbs. (658 kg)
Hitch Towin g Capacity 1500 lbs. (680.4 kg)
Hitch Tongue Capacity 150 lbs. (68 kg)
Cargo System

Lock & Ride

®

Seating 2

83

SPECIFICATIONS

POLARIS M1400

Brake System

Brakes 4-Wheel hydraulic disc w/dual bore front calipers

Engine and Suspension

Engine Dual overhead cam, 4 valve 4 stroke single cylinder
Displacement 325 cc
Bore x Stroke (mm) 78mm x 68mm
Alternator Output 560 W @ 3000 RPM
Compression Ratio 11.5:1
St arting System Electric
Fuel System Electronic Fuel Injection
Ignition Timing ECU Controlled

32° +/- 2° @ 5000 RPM
Sp ark Plug NGK MR7F / .031” (0.7-0.9 mm)
Lubrication System Wet Sump
Cooling Liquid
Front suspension Independent Macpherson struts w/5 in. (12.5 cm) travel
Rear suspension Dual A-Arm w/6 in. (15 cm) travel
Tire size 23x8.5-12
Tire pressure 32 psi (220 kPa)
Throttle Body Size 36 mm
Ignition System Digital CDI
Driving System Type PVT
Shift Type Single Lever (console)
Gear Reduction - Low 28.84:1
Gear Reduction - Reverse 25.83:1
Gear Reduction - High 9.65:1
Drive Ratio - Front 3.818:1

Features

Cup holders Dual cup holders
Auxiliary power 12-volt accessory outlet
Headlights/taillights Dual 50-watt
Brake lights LED 1.8 watts at 12 volts
Storage Glove box

84

POLARIS PRODUCTS

Part Number Description

Engine Lubricant

2870791 Fogging Oil (12 oz./355 ml Aerosol)
2876244 PS-4 Full Synthetic 5W-50 4-Cycle Oil (qt./.95 l)
2876245 PS-4 Full Synthetic 5W-50 4-Cycle Oil (gal./3.8 l)
2878920 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (qt./.95 l)
2878919 PS-4 Extreme Duty Synthetic 10W-50 4-Cycle Oil (gal./3.8 l)

Gearcase / Transmission Lubricants

2878068 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (qt./.95 l)
2878069 AGL Full Synthetic Gearcase Lubricant & Transmission Fluid (gal./3.8 l)
2877922 Demand Drive Fluid (qt./.95 l)
2877923 Demand Drive Fluid (gal./3.8 l)
2870465 Pump for Gallon (3.8 l) Jug

Coolant

2880514 Antifreeze 50/50 Premix (qt./.95 l)
2880513 Antifreeze 50/50 Premix (gal./3.8 l)

Grease / Specialized Lubricants

2871312 Grease Gun Kit, All Season Grease
2871322 All Season Grease (3 oz./89 ml cartridge)
2871423 All Season Grease (14 oz./414 ml cartridge)
2876160 ATV Angle Drive Fluid (qt./.95 l)
2872276 ATV Angle Drive Fluid (2.5 gal./9.5 l)
2871460 Premium Starter Grease
2871515 U-Joint Grease (3 oz./89 ml cartridge)
2871551 U-Joint Grease (14 oz./414 ml cartridge)
2871329 Dielectric Grease (Nyogel™)

Additives / Miscellaneous

2871326 Carbon Clean
2870652 Fuel Stabilizer
2872189 DOT 4 Brake Fluid
2871956 Loctite™ 565 Thread Sealant
2859044 POLARIS Battery Tender™ Charger
2521372 POLARIS Air Filter

85

TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause Solution

Driving onto a pickup or tall
trailer in high range

Use low range during loading.

Starting out going up a steep
incline

Use low range. See warnings on page 34.

Driving at low RPM or ground
speed (3-7 MPH)

Drive at a higher speed or use low range more frequently.

Insufficient warm-up at low
ambient temperatures

Warm the engine at least 5 minutes. With the transmission in neutral,
advance the throttle to about 1/8 throttle in short bursts, 5 to 7 times. The

belt will become more flexible and prevent belt burning.
Slow/easy clutch engagement Use the throttle quickly and effectively.
T owing/pushing at low RPM/low

ground speed

Use low range only.

Utility use/plowing Use low range only.
Stuck in mud or snow Shift the transmission to low range and carefully use fast, aggressive throt-

tle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle roll-

over.
Climbing over large objects from

a stopped position

Shift the transmission to low range and carefully use fast, brief, aggressive

throttle application to engage clutch.

WARNING: Excessive throttle may cause loss of control and vehicle roll-

over.
Belt slippage from water or snow

ingestion into the PVT system

Dry out the PVT. See page 65. Inspect clutch seals for damage if repeated

leaking occurs.
Clutch malfunction Your dealer can assist.
Poor engine performance Check for fouled plugs or foreign material in fuel tank or fuel lines. Your

dealer can assist.
Slippage from failure to warm up

belt

Always warm up the belt by operating below 30 MPH for one mile (5

miles or more when temperature is below freezing).
Wrong or missing belt Install the recommended belt.
Improper break-in Always break in a new belt and /or clutch . See pages 29 and 63.

86

TROUBLESHOOTING

Engine Doesn't Turn Over

Engine Turns Over, Fails to Start

Engine Backfires

Engine Pings or Knocks

Possible Cause Solution

Low battery voltage Recharge the battery to 12.8 VDC
Loose battery connections Check all connections and tighten
Loose solenoid connections Check all connections and tighten
Loose electronic control box connections Inspect, clean, reinstall connectors

Possible Cause Solution

Out of fuel Refuel
Clogged fuel filter Your dealer can assist.
Water is present in fuel Drain the fuel system and refuel
Old or non-recommended fuel Replace with fresh recommended fuel
Fouled or defective spark plug Inspect plug and replace if necessary
No spark to spark plug Inspect plug and replace if necessary
Water or fuel in crankcase Your dealer can assist.
Low battery voltage Recharge the battery to 12.8 VDC
Mechanical failure Your dealer can assist.

Possible Cause Solution

Weak spark from spark plug Inspect, clean and/or replace spark plug
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Old or non-recommended fuel Replace with fresh recommended fuel
Incorrectly installed spark plug wires Your dealer can assist.
Incorrect ignition timing Your dealer can assist.
Mechanical failure Your dealer can assist.
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with fresh recommended fuel

Possible Cause Solution

Poor quality or low octane fuel Replace with recommended fuel
Incorrect ignition timing Your dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plug

87

TROUBLESHOOTING

Engine Runs Irregularly, Stalls or Misfires

Engine Stops or Loses Power

Possible Cause Solution

Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug wires Your dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Water present in fuel Replace with new fuel
Low battery voltage Recharge battery to 12.8 VDC
Kinked or plugged fuel tank vent line Inspect and replace
Incorrect fuel Replace with recommended fuel
Clogged air filter Inspect and clean or replace
Low fuel pressure Your dealer can assist.
Other mechanical failure Your dealer can assist.

Possible Lean Fuel Cause Solution

Low or contaminated fuel Add or change fuel, clean the fuel system
Low octane fuel Replace with recommended fuel
Clogged fuel filter Your dealer can assist.

Possible Rich Fuel Cause Solution

Fuel is very high octane Replace with lower octane fuel

Possible Cause Solution

Out of fuel Refuel
Kinked or plugged fuel vent line Inspect and replace
Water is present in fuel Replace with new fuel
Fouled or defective spark plug Inspect, clean and/or replace spark plug
Worn or defective spark plug wires Your dealer can assist.
Incorrect spark plug gap or heat range Set gap to specs or replace plug
Loose ignition connections Check all connections and tighten
Low battery voltage Recharge the battery to 12.8 VDC
Incorrect fuel Replace with fresh recommended fuel
Clogged air filter Inspect and clean or replace
Other mechanical failure Your dealer can assist.
Overheated engine Clean radiator screen and core, clean engine exterior.

Your dealer can assist.

88

WARRANTY

Limited Warranty

POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a ONE YEAR LIMITED
WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship.
POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS
standard 5100-1C for at least 1000 hours when subjected to normal use and when maintenance and installation
are in accordance with POLARIS recommendations.

This warranty covers parts and labor charges for repair or replacement of defective par ts and begins on the date of
purchase by the original retail purchaser. This warranty is transferable to another owner during the warranty
period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The
duration of this warranty may vary by international region based upon local laws and regulations.

Registration

At the time of sale, the W arranty Registratio n Form must be completed by your dealer and submitted to
POLARIS within ten days of purchase. Upon receipt of this registration, POLARIS will record the registration for
warranty. No verification of registration will be sent to the purchaser as the copy of the Warranty Registration
Form will be your proof of warranty coverage. If you have not signed the original registration and received the
customer copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE ALLOWED
UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS. Initial dealer preparation and set-up of your
vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper
dealer set-up will void your warranty coverage.

Warranty Coverage And Exclusions:

Limitations Of Warranties And Remedies

This POLARIS limited warranty excludes any failures that are not caused by a defect in material or
workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty
also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling. This
warranty also does not cover any vehicle, component, or part that has been altered structurally, modified,
neglected, improperly maintained or used for racing, competition or purposes other than for which it was
designed.

This warranty excludes damages or failures resulting from improper lubrication; improper engine timing;
improper fuel; surface imperfections caused by external stress, heat, cold or contamination; operator error or
abuse; improper component alignment, tension, adjustment or altitude compensation; snow, water, dirt or other
foreign substance ingestion/contamination; improper maintenance; modified components; use of aftermarket or
unapproved components, accessories, or attachments; unauthorized repairs; or repairs made after the warranty
period expires or by an unauthorized repair center.

89

WARRANTY

Warranty Coverage And Exclusions:

Limitations Of Warranties And Remedies

This warranty excludes damages or failures caused by abuse, accident, fire, or any other ca use o ther than a defect
in materials or workmanship and provides no coverage for consumable components, general wear items, or any
parts exposed to friction surfaces, stresses, environmental conditions and/or contamination for which they were
not designed or not intended, including but not limited to the following items:

Lubricants and Fluids

1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of
POLARIS engine oil.

2. Damage or failure resulting from the use of non-recommended lubricants or fluids is not covered by this
warranty.

This warranty provides no coverage for personal loss or expense, including mileage, transportation costs, hotels,
meals, shipping or handling fees, product pick-up or delivery, replacement rentals, loss of product use, loss of
profits, or loss of vacation or personal time.

THE EXCLUSIVE REMEDY FOR BREACH OF THIS WARRANTY SHALL BE, AT POLARIS' OPTION,
REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS, COMPONENTS, OR PRODUCTS. THE
REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONL Y REMEDIES AVAILABLE TO ANY
PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY
PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT,
NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTAL,
INCIDENTAL, AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE.

THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS
LIMITED WARRANTY. ALL OTHER IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO
THE IMPLIED WARRANTY OF MERCHANTABILITY) ARE LIMITED IN DURATION TO THE ABOVE
ONE YEAR WARRANTY PERIOD. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED
IN THIS WARRANTY. SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF
INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF
IMPLIED WARRANTIES, SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF
INCONSISTENT WITH CONTROLLING STATE LAW.

• Wheels and tires • Finished and unfinished surfaces

• Suspension components • Carburetor/Throttle body components

• Brake components • Engine components

• Seat components • Drive belts

• Clutches and components • Hydraulic components and fluids

• Steering components • Circuit breakers/Fuses

• Batteries • Electronic components

• Light bulbs/Sealed beam lamps • Spark plugs

•Filters •Sealants

• Lubricants • Coolants

• Bushings • Bearings

90

WARRANTY

How To Obtain Warranty Service

If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting
warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF
TRANSPORTATION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY.) POLARIS suggests that
you use your original selling dealer; however, you may use any POLARIS Servicing Dealer to perform warranty
service.

In the Country where your product was purchased:

Warranty or Service Bulletin repairs must be done by an authorized POLARIS dealer. If you move or are
traveling within the country where your product was purchased, Warranty and Service Bulletin repairs may be
requested from any authorized POLARIS dealer that sells the same line as your product.

Outside the Country where your product was purchased:

If you are traveling temporarily outside the country where your product was purchased, you should take your
product to an authorized POLARIS dealer. You must show the dealer photo identification from the country of the
selling dealer's authorized location as proof of residence. Upon residence verification, the servicing dealer will be
authorized to perform the warranty repair.

If you move:

If you move to another country , be sure to contact POLARIS Customer Assistance and the customs department of
the destination country before you move. Product importation rules vary considerably from country to country.
You may be required to present documentation of your move to POLARIS in order to continue your warranty
coverage. You may also be required to obtain documentation from POLARIS in order to register your product in
your new country. You should warranty register your product at a local POLARIS dealer in your new country
immediately after you move to continue your warranty coverage and to ensure that you receive information and
notices regarding your vehicle.

If you purchase from a private party:

If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the
product was originally purchased, all warranty coverage will be denied. You must nonetheless register your
product under your name and address with a local POLARIS dealer in your country to ensure that you receive
safety information and notices regarding your product.

Exported Products

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE
BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE
SELLING DEALER'S AUTHORIZED LOCATION. This policy does not apply to products that have received
authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an
authorized dealer to determine this product's warranty or service coverage if you have any questions. This policy
does not apply to products registered to government officials or military personnel on assignment outside the
country of the selling dealer's authorized location. This policy does not apply to Safety Bulletins.

91

WARRANTY

Notice

If your product is registered outside of the country where it was purchased and you have not followed the
procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind,
other than safety bulletins. Products registered to government officials or military personnel on assignment
outside of the country where the product was purchased will continue to be covered by the Limited Warranty.

Please work with your dealer to resolve any warranty issues. Should your dealer require any additional assistance,
they will contact the appropriate person at POLARIS.

This warranty gives you specific legal rights, and you may also have other rights which vary from state to state or
in different countries. If any of the above terms are void because of federal, state, local law, all other warranty
terms will remain in effect.

For questions call POLARIS Customer Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334

U.S.A. EPA Emissions Limited Warranty

This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle.
POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is
designed, built and equipped so it conforms with applicable U.S. Environmental Protection Agency emission
regulations. POLARIS warrants that the vehicle is free from defects in materials and workmanship that would
cause it to fail to meet these regulations.

The warranty period for off road vehicles 100cc or greater emissions-certified vehicles starts on the date of
purchase by original retail purchaser and continues for a period of 500 hours of engine operation, 5000 kilometers
(3100 miles) of vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. The
warranty period for ATVs less than 100cc emissions-certified vehicles starts on the date of purchase by original
retail purchaser and continues for a period of 250 hours of engine operation, 2500 kilometers (1550 miles) of
vehicle travel, or 30 calendar months from the date of purchase, whichever comes first. This EPA emissions
warranty period is extended for at least as long as the standard factory warranty that POLARIS provides on the
vehicle as a whole. The EPA emissions warranty period does not further extend if you purchase additional
warranty coverage in the form of a service contract or other paid wa rranty extension, but emission-related parts
may be covered subject to the terms of any such paid service contract or paid warranty extension.

This emissions limited warranty covers components whose failure increases the vehicle's regulated emissions,
and it covers components of systems whose only purpose is to control emissions. Repairing or replacing other
components not covered by this warranty is the responsibility of the vehicle owner. This emissions limited
warranty does not cover components whose failure does not increase the vehicle's regulated emissions.

For exhaust emissions, emission-related components include any engine parts related to the following systems:

The following parts are also considered emission-related components for exhaust emissions:

• Air-induction system • Ignition system

• Fuel system • Exhaust gas recirculation systems

• Aftertreatment devices • Sensors

• Crankcase ventilation valves • Electronic control units

92

WARRANTY

U.S.A. EPA Emissions Limited Warranty

The following parts are considered emission-related components for evaporative emissions:

*As related to the evaporative emission control system.
Emission-related components also include any other part whose only purpose is to reduce emissions or whose

failure will increase emissions without significantly degrading engine/equipment performance. The exclusive
remedy for breach of this limited warranty shall be, at the exclusive option of POLARIS, repair or replacement of
any defective materials, components or products. THE REMEDIES SET FORTH IN THIS LIMITED
WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT
OR OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES
IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY
FAILED OF ITS ESSENTIAL PURPOSE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF
MERCHANT ABILITY AND FITNESS FOR A PAR TICULAR PURPOSE) ARE LIMITED IN DURATION TO
THE WARRANTY PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRANTIES
NOT STATED IN THIS WARRANTY. Some states do not allow limitations on how long an implied warranty
lasts, so the above limitation may not apply if it is inconsistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workmanship. This limited warranty
does not cover damage due to accidents, abuse or improper handling, maintenance or use. This limited warranty
also does not cover any engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or defects caused by fire,
explosions or other similar causes beyond the control of POLARIS.

Owners are responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS
may deny warranty claims for failures that have been caused by the owner's or operator's improper maintenance
or use, by accidents for which POLARIS has no responsibility , or by acts of God.

Any qualified repair shop or person may maintain, replace, or repair the emission control devices or systems on
your vehicle. An authorized POLARIS dealer can perform any service that may be necessary for your vehicle.
POLARIS also recommends POLARIS parts, however equivalent parts may be used for such service. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufactur er reduces the
effectiveness of the vehicle's emission controls. Tampering with emission controls is prohibited by federal law.

California Residents

Certain POLARIS Off-Road Vehicles are available in 49-state and 50-state versions. Only the 50-state models are
certified for sale in California. The 50-state models available for sale i n Cal iforni a are identified by the l etter “B”
in the ninth position of the model number (e.g., R16RTE87B). The POLARIS 50-state models are designed and
built with features such as a reduced cargo box capacity. Any modifications to these features may be a violation
of the applicable California regulations and may void this limited emissions warranty offered by the
manufacturer.

If you have any questions regarding your warranty rights and responsibilities, please contact POLARIS Customer
Assistance:

United States & Canada: 1-800-POLARIS (1-800-765-2747)
French: 1-800-268-6334

• Fuel Tank • Vacuum Control Diaphragms*

• Fuel Cap • Control Cables*

• Fuel Line • Control Linkages*

• Fuel Line Fittings • Purge Valves

• Clamps* • Vapor Hoses

• Pressure Relief Valves* • Liquid/Vapor Separator

• Control Valves* • Carbon Canister

• Control Solenoids* • Canister Mounting Brackets

• Electronic Controls* • Carburetor Purge Port Connector

93

MAINTENANCE LOG

Use the following chart to record periodic maintenance.

DATE MILES (KM)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

94

MAINTENANCE LOG

DATE MILES (K M)

OR HOURS

TECHNICIAN SERVICE PERFORMED / COMMENTS

95

INDEX

A

Adjustment, Headlight Beam . . . . . . . . . . . . . . . . 73

Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Air Filter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 66

Auxiliary 12-Volt Terminal Board . . . . . . . . . . . . 20

Auxiliary Outlets. . . . . . . . . . . . . . . . . . . . . . . . . . 20

Axle Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . 70

B

Battery

Charging (Conventional) . . . . . . . . . . . . . . . . . 77

Charging (Sealed) . . . . . . . . . . . . . . . . . . . . . . 77

Extreme Use. . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fluid (Conventional) . . . . . . . . . . . . . . . . . . . . 74

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Belt Burning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Belt Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Belt Replacement . . . . . . . . . . . . . . . . . . . . . . 63-64

Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Brake Pedal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Brakes

Brake Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Brake Inspection . . . . . . . . . . . . . . . . . . . . . . . 68

Break-In Period. . . . . . . . . . . . . . . . . . . . . . . . . . . 29

C

Cab Frame, OPS . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Chart, Periodic Maintenance. . . . . . . . . . . . . . 52-53

Check Engine Indicator . . . . . . . . . . . . . . . . . . . . 28

Cleaning and Storage . . . . . . . . . . . . . . . . . . . 78-80

Cleaning the Air Filter . . . . . . . . . . . . . . . . . . . . . 66

Cleaning the Exhaust System . . . . . . . . . . . . . . . . 67

Cleaning the Spark Arrester . . . . . . . . . . . . . . . . . 67

Component Locations. . . . . . . . . . . . . . . . . . . . . . 18

Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19-21

Coolant Level, Overflow Bottle . . . . . . . . . . . . . . 62

Coolant, Adding or Changing. . . . . . . . . . . . . . . . 61

Cooling Fan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . 61-62

Crankcase Emission Control System . . . . . . . . . . 50

D

Display Units, Standard/Metric . . . . . . . . . . . . . . 26

Drive Belt Wear . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Drivetrain Break-In. . . . . . . . . . . . . . . . . . . . . . . . 29

Driving Downhill . . . . . . . . . . . . . . . . . . . . . . . . . 34

Driving in Reverse . . . . . . . . . . . . . . . . . . . . . . . . 35

Driving on a Sidehill. . . . . . . . . . . . . . . . . . . . . . . 35

Driving on Slippery Surfaces . . . . . . . . . . . . . . . . 32

Driving Over Obstacles . . . . . . . . . . . . . . . . . . . . 33

Driving Procedure. . . . . . . . . . . . . . . . . . . . . . . . . 31

Driving Through Water . . . . . . . . . . . . . . . . . . . . 36

Driving Uphill. . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Driving with a Passenger . . . . . . . . . . . . . . . . . . . 32

Driving, After Driving in Water. . . . . . . . . . . . . . 65

Drying the Transmission. . . . . . . . . . . . . . . . . . . . 65

Dumping the Cargo Box. . . . . . . . . . . . . . . . . . . . 39

E

Emissions Limited Warranty . . . . . . . . . . . . . 91-92

Engine Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Engine Fogging. . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57

Equipment Modifications . . . . . . . . . . . . . . . . . . . 13

Error Codes, Engine . . . . . . . . . . . . . . . . . . . . . . . 28

Exhaust Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . 67

Exhaust Emission Control System . . . . . . . . . . . . 50

Exhaust System Warning . . . . . . . . . . . . . . . . . . . 67

Extreme Use Battery. . . . . . . . . . . . . . . . . . . . . . . 22

Eye Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

F

Filter Cleaning, Air. . . . . . . . . . . . . . . . . . . . . . . . 66

Filter Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Filter, Air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Fluid Change

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . 59

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fluid Check

Coolant (Overflow Bottle). . . . . . . . . . . . . . . . 62

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . 59

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Fluid Levels During Storage. . . . . . . . . . . . . . . . . 80

Fluid Recommendation, Gearcase . . . . . . . . . 54, 58

Fluid, Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Fluid,Battery Fluid . . . . . . . . . . . . . . . . . . . . . . . . 74

Fogging the Engine. . . . . . . . . . . . . . . . . . . . . . . . 80

Fouled Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Fuel Cap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Fuel Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Fuel Stabilizer. . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Fuel Tank Filler Cap. . . . . . . . . . . . . . . . . . . . . . . 22

Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Fuse Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 71

G

Gap, Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Gasoline Handling . . . . . . . . . . . . . . . . . . . . . . . . 15

Gear Selector . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Gearcase Specification Chart . . . . . . . . . . . . . . . . 58

Gearcase, Front. . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Gearcase, Main . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Gearcases . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58-59

Gears, Shifting . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Gross Vehicle Weight Rating. . . . . . . . . . . . . . . . 13

GVWR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

H

Hard Hat/Helmet. . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hauling Cargo. . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Headlight Beam Adjustment. . . . . . . . . . . . . . . . . 73

Headlight Lamp Replacement . . . . . . . . . . . . . . . 72

Hitch Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Hitch Weight. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

I

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Immersion of Vehicle . . . . . . . . . . . . . . . . . . . . . . 65

Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Instrument Cluster . . . . . . . . . . . . . . . . . . . . . 24-28

96

Index

K

Key, Periodic Maintenance Chart . . . . . . . . . . . . 51

L

Light Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Lights

Brake Lights . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Headlight Beam Adjustment. . . . . . . . . . . . . . 73

Headlight Lamp Replacement . . . . . . . . . . . . 72

Lubricants, Gearcase . . . . . . . . . . . . . . . . . . . . . . 58

Lubrication Recommendations . . . . . . . . . . . . . . 54

M

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Maintenance, Periodic . . . . . . . . . . . . . . . . . . . 51-53

Metric Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Mode Button . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Modifications to Vehicle . . . . . . . . . . . . . . . . . . . 13

N

Noise Emission Control System . . . . . . . . . . . . . 50

O

Obstacles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Occupant Protective Structure. . . . . . . . . . . . . . . 22

Oil Change

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . 56-57

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . 59

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . 58

Oil Check

Engine Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Front Gearcase . . . . . . . . . . . . . . . . . . . . . . . . 59

Main Gearcase . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . 58

Oil Recommendation, Gearcase s. . . . . . . . . . . . . 58

Oil, Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . 55-57

Operation on Public Lands . . . . . . . . . . . . . . . . . 50

Operator Safety . . . . . . . . . . . . . . . . . . . . . . . . 11-17

OPS Cab Frame . . . . . . . . . . . . . . . . . . . . . . . . . . 22

P

Parking on an Incline. . . . . . . . . . . . . . . . . . . . . . 36

Parking the Vehicle . . . . . . . . . . . . . . . . . . . . . . . 35

Periodic Maintenance Chart . . . . . . . . . . . . . . 51-53

Personal Protective Equipment . . . . . . . . . . . . . . 10

Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Plug Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Plugs, Fouled . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Polishing the Vehicle. . . . . . . . . . . . . . . . . . . . . . 79

Pre-Ride Inspection . . . . . . . . . . . . . . . . . . . . . . . 30

Pressure, Tire. . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

PVT Break-In. . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

PVT Drying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

PVT System. . . . . . . . . . . . . . . . . . . . . . . . . . . 64-65

PVT System Operation . . . . . . . . . . . . . . . . . . . . 63

PVT Warning. . . . . . . . . . . . . . . . . . . . . . . . . . 63-65

PVT, Cleaning Debris . . . . . . . . . . . . . . . . . . . 63-64

R

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Registration, Warranty . . . . . . . . . . . . . . . . . . . . . 88

Removing the Vehicle from Storage . . . . . . . . . . . 81

Reverse Operation . . . . . . . . . . . . . . . . . . . . . . . . . 35

Rider Information Center . . . . . . . . . . . . . . . . 25-28

S

Safety Gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Glasses . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-10

Safety Shoes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Safety Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety, Winch Maintenance. . . . . . . . . . . . . . . . . . 49

Seat Belt Inspection. . . . . . . . . . . . . . . . . . . . . . . . 23

Seat Belts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Seat Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Severe Use Definition . . . . . . . . . . . . . . . . . . . . . . 51

Shifter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Shifting Gears . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Shock Loading the Winch . . . . . . . . . . . . . . . . . . . 48

Shock Spring Adjustment . . . . . . . . . . . . . . . . . . . 69

Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Spark Arrester Warning. . . . . . . . . . . . . . . . . . . . . 67

Spark Arrester, Cleaning . . . . . . . . . . . . . . . . . . . . 67

Spark Plug Gap . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Spark Plug Inspection . . . . . . . . . . . . . . . . . . . . . . 60

Spark Plug Recommendations. . . . . . . . . . . . . . . . 60

Spark Plug Torque. . . . . . . . . . . . . . . . . . . . . . . . . 60

Spark Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Spark Plugs, Fouled. . . . . . . . . . . . . . . . . . . . . . . . 60

Specifications, Gearcase . . . . . . . . . . . . . . . . . . . . 58

Speed, Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . 24-28

Steering Wheel Inspection. . . . . . . . . . . . . . . . . . . 69

Storage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78-80

Storage Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Storage Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . 79-80

Storage, Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Storage, Covers . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Storage, Removal . . . . . . . . . . . . . . . . . . . . . . . . . 81

Storing the Vehicle . . . . . . . . . . . . . . . . . . . . . . . . 81

Switches

Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . 20

Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

97

Index

T

Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Throttle Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Tires

Nut Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Tread Depth . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Wheel Installation . . . . . . . . . . . . . . . . . . . . . . 71

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . 70

Torque, Spark Plug. . . . . . . . . . . . . . . . . . . . . . . . 60

Towing Loads. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Towing Speed. . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Towing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . . 38

Trailer Hitch Bracket . . . . . . . . . . . . . . . . . . . . . . 21

Transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Transmission Operation . . . . . . . . . . . . . . . . . 63-65

Transmission System . . . . . . . . . . . . . . . . . . . 64-65

Transmission Warning . . . . . . . . . . . . . . . . . . 63-65

Transmission, Drying . . . . . . . . . . . . . . . . . . . . . . 65

Transporting the Vehicle . . . . . . . . . . . . . . . . . . . 40

V

Vehicle Identification Numbers . . . . . . . . . . . . . . . 6

Vehicle Immersion . . . . . . . . . . . . . . . . . . . . . . . . 65

W

Warning Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Warning, Transmission Modification. . . . . . . 63-65

Washing the Vehicle. . . . . . . . . . . . . . . . . . . . . . . 78

Weight Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Weight, Hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Wheel Installation. . . . . . . . . . . . . . . . . . . . . . . . . 71

Wheel Nut Torque . . . . . . . . . . . . . . . . . . . . . . . . 70

Wheel Removal . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Winch Cable Care. . . . . . . . . . . . . . . . . . . . . . . . . 47

Winch Maintenance and Service Safety. . . . . . . . 49

Winch Operation. . . . . . . . . . . . . . . . . . . . . . . 43-46

Winch Safety Precautions. . . . . . . . . . . . . . . . 41-42

Winch Shock Loading . . . . . . . . . . . . . . . . . . . . . 48