Polaris RANGER RZR EPS, 2009 Ranger RZR, 2010 RANGER RZR, 2010 RANGER RZR EPS Owner's Manual

Pantone 426C

Owner's Manual

for Maintenance and Safety

RANGER RZR
RANGER RZR EPS

TM

TM

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.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Pantone 426C

WARNING

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com

Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone]

Part No. 9922955 Rev 01
Printed in USA

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

• without first viewing safety video and quick start guide.

• with more than one passenger.

• on hills steeper than 15 degrees.

• on public roads.

• on paved surfaces - pavement may seriously affect handling and control.

ALWAYS:

• keep hands and feet inside vehicle.

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

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

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

• make sure passenger reads and understands all safety labels.

ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR
OPERATOR AND PASSENGER

NEVER USE ON PUBLIC ROADS - NEVER USE WITH DRUGS OR ALCOHOL
LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND

WARNINGS. IF OWNER’S MANUAL IS MISSING, CONTACT A POLARIS
DEALER FOR A REPLACEMENT.

• with non-Polaris approved accessories - they may seriously affect stability.

1

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world­wide family of Polaris owners. We proudly produce an exciting line of
utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles
We believe Polaris sets a standard of excellence for all utility and recre-

ational 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 should be
performed only by a Factory Certified Master Service Dealer (MSD)
Technician.

Your Polaris dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your ser­vice needs during, and after, the warranty period.

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

2

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

Copyright 2010 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2010 RANGER RZR/RZR EPS Owner’s Manual
P/N 9922955

3

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Emission Control Systems . . . . . . . . . . . . . . . 66

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

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 120

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 122

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 123

Declaration of Conformity . . . . . . . . . . . . . . . 127

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

4

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

A NOTICE indicates a situation that may 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 heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your Polaris vehicle is not a toy and can be
hazardous to operate. This vehicle handles differently than cars, trucks or other
off-road vehicles. A collision or rollover can occur quickly, even during routine
maneuvers like turning, or driving on hills or over obstacles, if you fail to take
proper precautions.

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

• Complete the New Operator Driving Procedures outlined on pages 54-55.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.

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

WARNING

6

INTRODUCTION

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Vehicle Identification Number: ______________________________________________

Engine Serial Number: ___________________________________________________

Key Number ____________________________________________________________

Engine Serial Number

Key

Number

Vehicle Identification
Number

####

7

SAFETY

Equipment Modifications

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

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

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

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.

8

SAFETY

Safe Riding Gear

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

Helmet

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

Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.

Helmet

Eye

Protection

Gloves

Sturdy

Footwear

Long

Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

Wear sturdy footwear. Do not ride a Polaris vehicle with bare feet.

Clothing

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

10

SAFETY

Safety Warnings

Failure to operate this vehicle properly can result in a collision, loss of control,
accident or overturn, 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.

Operating Without Instruction

Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain. Complete the New Operator
Driving Procedures outlined on pages 54-55.

All operators must read and understand the
owner's manual and all warning and instruction
labels before operating the vehicle. Never allow a
guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures
outlined on pages 54-55.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age or anyone without a valid driver’s license. Never operate
with a passenger under the age of 12. Make sure any passenger is tall enough
to comfortably and safely reach the hand holds and place both feet on the floor.

Accessories

Non-approved accessories may seriously affect vehicle stability. Using
accessories not approved by Polaris for use on this vehicle could cause loss of
control or an accident. Never operate with accessories not approved by Polaris
for use on this vehicle.

Using Alcohol or Drugs

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

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

WARNING

11

SAFETY

Safety Warnings

Failure to Inspect Before Operating

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

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

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

Protective Apparel

Riding in this vehicle without wearing an
approved helmet and protective eyewear
increases the risk of a serious injuries in
the event of an accident.

Operator and passenger must always
wear an approved helmet that fits properly
and eye protection (goggles or face
shield).

Seat Belts

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

Cab Nets/Side Guards

Riding in this vehicle without using the cab nets and side guards increases the
risk of serious injury or death in the event of an accident or overturn. Always use
the cab nets and side guards while riding in this vehicle.

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

12

SAFETY

Safety Warnings

Carrying a Passenger

Never carry a passenger until you have operated this vehicle for at least two
hours and have completed the New Operator Driving Procedures outlined on
pages 54-55.

Carrying Multiple Passengers

Carrying more than one passenger in this
vehicle can affect the operator’s ability to
steer and operate the controls, which
increases the risk of loss of control and
accident or overturn.

Never carry more than one passenger in this
vehicle.

Passengers in the Cargo Box

Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a passenger
to ride in the cargo box. A passenger must
always be seated in the passenger seat with
seat belt secured.

Operating on Pavement

Operating this vehicle on paved surfaces
(including sidewalks, paths, parking lots, and
driveways) may seriously affect handling and control of the vehicle, and may
cause the vehicle to go out of control. This vehicle's tires are designed for off­road use only, not for use on pavement.

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

Operating on Public Roads

Operating this vehicle on public streets,
roads or highways could result in a
collision with another vehicle.

Never operate this vehicle on any public
street, road or highway, including dirt and
gravel roads.

In many areas it's illegal to operate
vehicles of this type on public streets,
roads and highways.

13

SAFETY

Safety Warnings

Operating at Excessive Speeds

Operating this vehicle at
excessive speeds increases the

operator's risk of losing control.
Always operate at a speed that's

appropriate for the terrain, the
visibility and operating
conditions, your skills and your
passenger’s skills.

Turning Improperly

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

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

Physical Control of the Vehicle

Removing hands from the steering wheel or hand holds or removing feet from
the floor while riding increases the risk of loss of control and accident or
overturn.

The operator should always keep both hands on the steering wheel during
operation. A passenger should always be seated in the passenger seat with
both feet on the floor and with both hands securely grasping the hand holds.

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

Jumps and Stunts

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

14

SAFETY

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause
loss of control or overturn. Always follow
proper procedures for traveling down hills
as described in the owner's manual.

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

• Always check the terrain carefully
before descending a hill.

• Never travel down a hill at high speed.

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

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Use extreme caution
when operating on hills. Always follow
proper procedures for hill climbing as
described in the owner's manual. See
page 58.

+15°

+15°

15

SAFETY

Safety Warnings

Crossing Hillsides

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

If crossing a hillside is unavoidable, always
follow proper procedures as described in
the owner's manual. See page 59.

Stalling While Climbing a Hill

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

If you lose all forward speed:

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

Operating in Unfamiliar Terrain

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

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

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

16

SAFETY

Safety Warnings

Operating on Slippery Terrain

Operating on excessively rough, slippery
or loose terrain could cause loss of
traction, loss of control, accident or
overturn.

Do not operate on excessively rough,
slippery or loose terrain. Always use extra
caution on rough, slippery or loose terrain.

Operating Improperly in
Reverse

Improperly operating in reverse could
result in a collision with an obstacle or
person. Always follow proper operating
procedures as outlined in this manual.
See page 62.

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

Improper Tire Maintenance

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

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.

17

SAFETY

Safety Warnings

Operating Over Obstacles

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

Before operating in a new area,
check for obstacles. Never attempt
to operate over large obstacles such
as rocks or fallen trees. Always
follow the proper procedures
outlined in this manual when
operating over obstacles.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction
unexpectedly). Always follow proper procedures for operating on slippery
surfaces as described in the owner's manual.

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.

Do not operate on excessively slippery surfaces.

Operating Through Water

Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, overturn or accident. Never
operate in fast-flowing water or in water
that exceeds the recommended
maximum depth.

Always follow proper procedures for
operating in water as described in the
owner's manual.

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

18

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Always follow the instructions in the
owner's manual for carrying cargo or
pulling a trailer.

• Never exceed the stated load capacity
for this vehicle.

• Cargo should be properly distributed and securely attached.

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

Operating on Frozen Bodies of
Water

Operating on frozen bodies of water can

result in

the vehicle and/or riders falling
through the ice. Never operate this vehicle on
a frozen body of water.

Operating a Damaged Vehicle

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

19

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and is explosive under certain conditions. Always
exercise extreme caution whenever handling gasoline.

• Always stop the engine when refueling.

• Always refuel outdoors or in a well ventilated area.

• Remove flammable material containers from the box before filling.

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

• Never refuel while a person is in the vehicle.

• Do not over fill 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.

Refueling

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

Remove flammable material containers from the box before filling.

Exposure to Exhaust

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

Operate this vehicle only outdoors or in well-ventilated areas.

Hot Exhaust Systems

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

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.

FOR MORE INFORMATION ABOUT SAFETY

call Polaris at 1-800-342-3764.

20

SAFETY

Safety Labels and Locations

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

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

Cargo Box Warning

Tire Pressure/Cargo Overload

Warning

21

SAFETY

Safety Labels and Locations

Cargo Box Warning

WARNING

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

• Never carry passengers in cargo box.

• Maximum 4X4 Box Load is 300 lbs. (136.4 kg)

Tire Pressure/Cargo Overload Warning

WARNING
IMPROPER TIRES, TIRE PRESSURE OR OVERLOADING can cause loss of

control resulting in SEVERE INJURY OR DEATH.
TIRE PRESSURE IN PSI (KPa):
4X4 - FRONT 8 (55.2) REAR 8 (55.2)
MAXIMUM WEIGHT CAPACITY INCLUDING DRIVER, PASSENGER, CARGO

AND ACCESSORIES: 4X4 is 740 LBS. (336.4 kg)
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.

Read Owner’s Manual for more detailed loading information.

7175103

22

SAFETY

Safety Labels and Locations

Cab Frame/Seat Belt Warning

WARNING

• ALWAYS WEAR YOUR SEAT BELT and make sure passenger wears seat
belt.

• ALWAYS SECURE CAB NETS.

• VEHICLE OVERTURN could cause severe injury or death. The cab frame is
not designed or intended to provide rollover protection.

7175100

Shift

Caution

Cab Frame/Seat

Belt Warning

Age

Warning

Overturn

Warning

23

SAFETY

Safety Labels and Locations

Shift Caution

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

When vehicle is stopped, place shift in the parked position.
APPLY BRAKE TO START

7174843

Age Warning

WARNING
Operating this vehicle if you are under the age

of 16 increases your chance of severe injury or
death.

NEVER operate this vehicle if you are under
age 16 or without a valid driver’s license.

7175101

Overturn Warning

WARNING
Improper operation can cause this vehicle to overturn and lead to serious injury

or death.
This vehicle handles differently than cars, trucks

or other off-road vehicles. In order to avoid
overturns:

• avoid sharp turns.

• never turn while applying heavy throttle.

• never make abrupt steering maneuvers.

• operate at speeds appropriate for your skills,
the conditions and the terrain.

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

7175105

24

SAFETY

Safety Labels and Locations

Passenger Safety Warning

WARNING
NEVER CARRY A PASSENGER UNDER AGE 12
NEVER CARRY MORE THAN ONE PASSENGER
NEVER RIDE AFTER USING DRUGS OR ALCOHOL
To reduce the risk of SEVERE INJURY or DEATH,

NEVER carry a passenger under age 12 or too small to
firmly plant feet on the floor and securely grasp hand
holds.

THE PASSENGER MUST ALWAYS:

• wear seat belt.

• use an approved helmet and protective gear.

• securely grasp hand holds and plant feet firmly on the
floor.

• tell operator to slow down or stop if uncomfortable - get
off and walk if conditions require.

• keep hands and feet inside vehicle at all times.

• watch for branches, brush, and other hazards that
could enter vehicle.

7175102

Passenger Safety

Warning

Discretionary

Warning

25

SAFETY

Safety Labels and Locations

Discretionary Warning

WARNING
Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER operate:

• without first viewing safety video and quick start guide.

• with more than one passenger.

• on hills steeper than 15 degrees.

• on public roads.

• on paved surfaces - pavement may seriously affect handling and control.

• with non-Polaris approved accessories - they may seriously affect stability.
ALWAYS:

• keep hands and feet inside vehicle.

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

• 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.
ALWAYS USE AN APPROVED HELMET AND

PROTECTIVE GEAR FOR OPERATOR AND
PASSENGER

NEVER USE ON PUBLIC ROADS
NEVER USE WITH DRUGS OR ALCOHOL
LOCATE AND READ OWNER’S MANUAL.

FOLLOW ALL INSTRUCTIONS AND
WARNINGS. IF OWNER’S MANUAL IS
MISSING, CONTACT A POLARIS DEALER FOR
A REPLACEMENT.

7175104

26

FEATURES AND CONTROLS

Component Locations

Your vehicle is equipped with upper and lower cab nets and side guards
on both sides of the vehicle. Cab nets and side guards must be used by
both operator and passenger at all times. Promptly replace worn or dam­aged cab nets with new cab nets, available from your authorized Polaris
dealer. The vehicle illustrated below is shown without cab nets only to
allow component identification. Always use the cab nets and side
guards.

Dash

Hip Bar

Fuel Tank

Cap

Seat Belts

Cargo Box

Seat

(storage under

driver’s seat)

Shifter

Passenger
Hand Hold

Cab

Nets

Side

Guard

27

FEATURES AND CONTROLS

Component Locations

Headlights

Brush Guard

Radiator

Steering

Wheel

Storage Compartment

(under hood)

Cab

Frame

28

FEATURES AND CONTROLS

Component Locations

Trailer Receiver Hitch Bracket

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

To avoid injury and property damage, always heed the warnings and
towing capacities outlined on pages 64-65.

Taillights

Receiver

Hitch

Muffler

(Spark Arrestor)

29

FEATURES AND CONTROLS

Rear Service Panel

The rear service panel is located behind the seats on the frame of the
vehicle. Remove the seats to access the service panel. Remove the ser­vice panel to access serviceable engine components and clutches.

Seats

Before operating the vehicle, always push down on both seat backs to
ensure the latches are secure.

Seat Adjustments

Loosen (do not remove) the four screws located on the seat bottom.
Slide the seat forward or rearward to the desired position. Tighten the
screws to 4 ft. lbs. (5.4 Nm). Do not overtighten.

Seat Removal

1. Pull up on the seat latch
lever located under the rear
edge of the seat.

2. Tilt the seat forward.

3. Lift the seat upward to

remove it from the vehicle.

4. Reverse this procedure to

reinstall the seat. Make
sure the seat tabs at the
front edge of the seat slide
under the seat retainer bar.

5. Press down firmly at the

rear of the seat to engage
the rear latch.

Front Seat

Retainer

Seat

Latch

30

FEATURES AND CONTROLS

Steering Wheel

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

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

Passenger Hand Hold

Always adjust the hand hold to a comfortable position for your passen­ger before operating. Make sure the adjustment pin and retainer are
securely installed after making adjustments.

1. Remove the retainer from the end of the adjustment pin.

2. Remove the pin from the post.

3. Slide the post inward or outward to the desired position.

4. Reinstall the pin through the mounting bracket hole, through both
post adjustment holes, and through the remaining bracket hole.

5. Reinstall the retainer to the pin.

Adjustment

Lever

A

d

j

u

s

t

m

e

n

t

P

o

s

i

t

i

o

n

H

o

l

e

s

Mounting

Bracket Holes

Adjustment

Pin

Pin

Retainer

31

FEATURES AND CONTROLS

Hood

Remove the hood to access the front storage compartment, the radiator
and the coolant overflow bottle.

1. If your model is
equipped with remov­able fasteners at the
upper hood edge,
remove the fasteners.

2. Grasp the upper hood

edge and pull upward
to disengage the hood
from the vehicle.

3. Continue pulling the

hood upward to dis­engage the lower
hood fasteners.

4. Lift the hood away

from the vehicle.

Storage Compartments

Remove the hood to access the front storage compartment. Remove the
driver’s seat to access the under-seat storage compartment. See page 29.

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.

Remove flammable material con­tainers from the box before filling.

Storage

Compartment

Upper

Fasteners

Lower

Fasteners

Fuel Cap

32

FEATURES AND CONTROLS

Cab Nets/Side Guards

Riding in this vehicle without
using the cab nets and side
guards increases the risk of
serious injury or death in the
event of an accident or over­turn. Cab nets and side guards
must be used by both operator
and passenger at all times.
Make sure all latches are
secure before operating the
vehicle.

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

Upper Cab Net Interference (Driver)

The upper cab net on the driver’s side may interfere with vehicle opera­tion for some operators due to operator body type, driving style or riding
apparel. Each operator must check for upper cab net interference before
operating the vehicle.

1. Complete the New Operator Driving Procedures outlined on pages
54-55.

2. Test for upper cab net interference by making slow speed turns to

the left and right. If the net interferes with operation, it should be
removed from the vehicle for this operator only. All other cab nets
must remain on the vehicle during operation. See page 33.

Upper Cab NetLower Cab Net

Latches

33

FEATURES AND CONTROLS

Cab Nets/Side Guards

Upper Cab Net Removal (Driver)

The upper cab net on the driver’s side
may be removed only if it interferes with
operation of the vehicle. All other cab
nets and side guards must remain
installed.

1. Using a T-25 torx bit and 7/16"
open end wrench, remove the
mounting screw and washers secur­ing the upper and lower cab nets to
the floor of the vehicle on the
driver’s side.

2. Reinstall the lower net with the

screw and all washers. Tighten the
screw securely.

3. Unclip the latches that secure the

upper net to the chassis and lower
net. See the photo on the previous
page.

4. Loop the free upper latch of the lower

cab net through the gap at the front of
the side guard and secure the latch,
adjusting strap length as needed.
Tighten the strap.

5. Reverse all steps to reinstall the upper

cab net. Always reinstall the upper

cab net for any other operator of the
vehicle.

Step 1

Screw

and

Washers

Step 2

Loop strap through gap

34

FEATURES AND CONTROLS

Seat Belts

This Polaris vehicle is equipped with three-point lap and diagonal seat
belts for the operator and passenger. Always make sure the seat belts are
secured for both the operator and passenger before riding.

To wear the seat belt properly, follow this procedure:

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

2. Push the latch plate into the

buckle until it clicks.

3. Release the strap, it will self-

tighten.

4. Press the red release latch on the

buckle to release the seat belt.

Seat Belt

Latches

Seat Belt

Buckles

35

FEATURES AND CONTROLS

Seat Belts

Seat Belt Inspection

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

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

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

releases freely.

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

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

4. To clean dirt or debris from the seat belts, sponge the straps with

mild soap and water. Do not use bleach, dye or household deter­gents.

36

FEATURES AND CONTROLS

Switches

Mode Switch

The yellow switch located
near the instrument gauge
is used to toggle through
mode options available
such as odometer, trip
meter, hour meter and
tachometer. See page 43
for operation of the
modes.

Auxiliary Outlet

The 12-volt accessory
plug receptacle has spade
connections on the back
that may be used to power
an auxiliary light or other
optional accessories or
lights. The connections are
under the dash.

Electronic Power Steering (EPS)

The EPS warning indicator briefly
illuminates when the key is turned to the
ON position. If the light remains on after
starting the engine, the EPS system is
inoperative. See your authorized Polaris
dealer for service.

Electronic power steering (if
equipped) engages when the
ignition key is turned to the ON
position. EPS remains engaged
whether the vehicle is moving
or idle.

Light Switch

AWD

Switch

12V Accessory

Outlet

Mode

Switch

Ignition

Switch

Instrument

Cluster

EPS Warning

Indicator

EPS Indicator

Power Steering Unit

(under cover)

37

FEATURES AND CONTROLS

Switches

Ignition Switch

The ignition switch is a three-position, key-operated switch. Use the
ignition switch to start the engine. See page 52 for starting procedures.

The key can be removed from the switch when it is in the OFF position.

Light Switch

Use the headlight switch to turn the lights on and
off. The ignition switch must be in the ON position
to operate the headlights.

All Wheel Drive (AWD) Switch

The AWD Switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD).

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

See page 40 for AWD operating instructions.

OFF The engine is off. Electrical circuits are off, except accessory 12V.

ON Electrical circuits are on. Electrical equipment can be used.

START Turn the key to the START position to engage the electric starter.

The key returns to the ON position when released.

ON

OFF

AWD

2WD

38

FEATURES AND CONTROLS

Gear Selector

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

sion function. See your dealer if you experience any shifting problems.

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

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

Using Low Range and High Range

Condition Range to Use

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

Operating in rough terrain or over obstacles Low

Loading the vehicle onto a trailer Low

Towing heavy loads Low

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

Gear

Selector

39

FEATURES AND CONTROLS

Brake Pedal

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

Throttle Pedal

Push the pedal down to
increase engine speed.
Spring pressure returns the
pedal to the rest position
when released. Always
check that the throttle pedal
returns normally before start­ing the engine. Make sure
there's adequate throttle
pedal freeplay. See page 96
for throttle pedal adjustment
procedures.

Throttle

Pedal

Brake
Pedal

40

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The All Wheel Drive system is con­trolled by the AWD switch. When
the switch is on 2X4, the vehicle is
in two-wheel drive at all times.
When the switch is on AWD, the
vehicle is in all wheel drive and the
AWD indicator light will be on.

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

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

Engaging AWD

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

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

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

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

41

FEATURES AND CONTROLS

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle
speed from the transmission. The instrument cluster measures distance
in miles as well as time, hours of operation and engine RPM. In addition
to showing vehicle speed, the speedometer needle flashes when the fuel
level is low.

Rider

Information

Center

Speedometer

Speedometer

Needle

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

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

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

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

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

2. AWD Indicator - This

indicator illuminates
when the AWD switch
is in the AWD posi­tion.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

6. Odometer/Tachometer/Tripmeter/ Hour Meter

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

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

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

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

1

2

345

6

7

8

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the yellow mode switch located near the instrument gauge to toggle
through the mode options. See page 36.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

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

Tip: 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.

44

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Place the transmission in neutral.

3. Hold the mode switch and turn the key switch on. Release the

switch as soon as the display is activated.

4. Use the mode switch to toggle through the diagnostic screens.

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

AWD Diagnostic Screen

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

Gear Circuit Diagnostic Screen

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

Programmable Service Interval

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

The service interval is programmed at 50 hours at the factory. To enable
or disable the service interval:

1. Enter the diagnostic mode. Toggle to the service interval screen.

2. Press and hold the mode switch for about seven (7) seconds, until
either ON or OFF appears in the Rider Information Center, depend­ing on your preference.

To reset the service interval:

1. Enter the diagnostic mode. Toggle to the service interval screen.

2. Press and hold the mode switch for 2-3 seconds, until the wrench
icon flashes. Release the switch.

3. Press and release the mode switch once to advance the setting by
one hour. Press and hold the mode switch to advance the hours
quickly.

Tip: If you scroll past the intended number, press and hold the switch until the

hours cycle back to zero.

4. When the desired setting is displayed, wait until the wrench icon
stops flashing. The new service interval is now programmed.

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Miles/Kilometers Toggle

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

1. Enter the diagnostic mode.

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

3. Press and hold the mode switch until the letters flash, then press and
release the switch once. When the display stops flashing, the mode
has been set.

Downloading Codes

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

See page 47 for Blink Codes and Failure Descriptions. Use the follow­ing procedure to download blink codes (failure codes) from the EFI
module.

1. Place the transmission in PARK.

2. Stop the engine.

3. Turn the key switch to the ON position.

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

47

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink
Code

Failure Description

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

48

OPERATION

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

Vehicle Break-in Period

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

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

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

Use of any oils other than those recommended by Polaris may cause
serious engine damage. We recommend the use of Polaris Premium
4 Synthetic Oil for your 4-cycle engine.

WARNING

49

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 31. Always exercise
extreme caution whenever handling gasoline.

2. Check the oil level. See page 75. Add the recommended oil as

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

3. Complete the New Operator Driving Procedures outlined on pages

54-55.

4. Avoid aggressive use of the brakes. See Brake System Break-in on

page 49.

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

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

on the daily pre-ride inspection checklist. See page 50.

7. Pull only light loads.

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

hours or one month.

Brake System Break-in

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

PVT Break-in (Clutches/Belt)

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

50

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 39

97

Brake fluid Ensure proper level 98

Front suspension Inspect, lubricate if necessary 72

Rear suspension Inspect, lubricate if necessary 72

Steering Ensure free operation 99

Tires Inspect condition and pressure 21

103

Wheels/fasteners Inspect, ensure fastener tightness 103

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels

42
75

Coolant level Ensure proper level 89

90

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 95

Indicator lights/switches Ensure proper operation 37

Air filter, pre-filter Inspect, clean 93

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

105

Brake light/tail lamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

107

Seat Latches Push down on both seat backs to

ensure the latches are secure

29

Seat Belts Check length of belt for damage,

check latches for proper operation

34

Cab Nets Check for wear or damage, ensure

proper installation

32

51

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this
vehicle.

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

driver’s license to operate this vehicle.

3. Never operate with a passenger under the age of 12. Never carry

more than one passenger in this vehicle. Never allow a passenger to
ride in the cargo box.

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

run in an enclosed area.

5. Never operate with accessories not approved by Polaris for use on

this vehicle.

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

pavement or on any public street, road or highway, including dirt
and gravel roads.

7. Drive in a manner appropriate for your skills and operating condi-

tions. Never operate at excessive speeds. Never attempt wheelies,
jumps, or other stunts. Keep both hands on the steering wheel dur­ing operation.

8. Never consume alcohol or drugs before or while operating this vehi-

cle.

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

Always maintain proper tire pressure.

10. Never operate a damaged vehicle. After any overturn or accident,

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

11. Never operate the vehicle on a frozen body of water.

12. Do not touch hot exhaust system components. Always keep com-

bustible materials away from the exhaust system.

13. Always remove the ignition key when the vehicle is not in use to

prevent unauthorized use.

52

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well-venti­lated area.

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

3. Place the transmission in PARK.

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

engine.

5. Turn the ignition key past the ON/RUN position to START. Engage

the starter for a maximum of five seconds. Release the key when the
engine starts.

6. If the engine does not start within five seconds, return the ignition

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

7. Vary the engine RPM slightly with the throttle to aid in warm up

until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Stopping the Engine

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

2. Place the transmission in PARK.

3. Turn the engine off.

Braking

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

2. Press on the brake pedal evenly and firmly. Practice starting and

stopping (using the brakes) until you're familiar with the controls.

53

OPERATION

Parking the Vehicle

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

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera­tion of this vehicle in your area. Respect the environment in which you
ride your vehicle. Find out where the designated riding areas are by con­tacting your Polaris dealer, a local riding club, or local officials.

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. Tread lightly. Operate with respect for the
terrain, avoid littering, and always stay on the designated trails.

Trail Etiquette

Always practice good etiquette when riding. Allow a safe distance
between your vehicle and other vehicles operating in the same area.
Communicate to oncoming operators by signaling the number of vehi­cles in your group. When stopping, move your vehicle to the edge of the
trail as far as possible to allow others to pass safely.

54

OPERATION

New Operator Driving Procedures

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

2. Perform the pre-ride inspection. See page 50.

3. Wear an approved helmet that fits properly and eye protection (gog-

gles or face shield).

4. Do not carry a passenger until you have at least two hours of driving

experience with this vehicle.

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

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

vehicle operation and handling.

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

8. Always use the cab nets and side guards while riding in this vehicle.

9. Place the transmission in PARK.

10. Start the engine.

55

OPERATION

New Operator Driving Procedures

11. Apply the brakes and shift into low gear.

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

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

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

15. Check for upper cab net interference. See page 33.

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

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

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

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

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

56

OPERATION

Driving with a Passenger

1. Complete the New
Operator Driving
Procedures outlined on
pages 54-55.

2. Perform the pre-ride

inspection. See page

50.

3. Make sure the

passenger is at least 12
years of age and is tall
enough to comfortably
and safely sit in the
passenger seat with the seat belt secured, put both feet on the floor
and grasp the hand holds.

4. Make sure the passenger is wearing appropriate riding gear, includ-

ing an approved helmet and eye protection. See page 8.

5. Make sure the passenger secures the seat belt.

6. Make sure all cab nets and side guards are properly secured.

7. Allow a passenger to ride only in the passenger seat.

8. Do not carry more than one passenger. Additional passengers can

affect the operator’s ability to steer and operate the controls.

9. Slow down. Always travel at a speed appropriate for your skills,

your passenger's skills, and operating conditions. Avoid unexpected
or aggressive maneuvers that could cause discomfort or injury to a
passenger.

10. Vehicle handling may change with a passenger and/or cargo on

board. Allow more time and distance for braking.

11. Always follow all operating guidelines as outlined on safety labels

and in this manual.

57

OPERATION

Driving on Slippery Surfaces

Skidding or sliding can cause loss of control or overturn (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.

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

Follow these precautions
when encountering slip­pery conditions:

1. Slow down before
entering slippery
areas.

2. Maintain a high level

of alertness, reading
the trail and avoiding
quick, sharp turns,
which can cause
skids.

3. Engage all-wheel

drive before wheels
begin to lose trac­tion.

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

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

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

skid. Never apply the brakes during a skid.

WARNING

58

OPERATION

Driving Uphill

Whenever traveling
uphill, follow these
precautions:

1. Always check the
terrain carefully
before ascending a
hill.

2. Avoid steep hills

(15° maximum). If
ascending a steeper
grade is unavoid­able, engage all­wheel drive before
ascending.

3. Drive straight uphill.

4. 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. Avoid unnecessary changes in speed or direction.

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

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

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

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

15° maximum

59

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

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

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

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

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid steep hills (15° maximum).

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

3. Always check the terrain carefully before descending a hill.

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

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

6. Apply the brakes lightly to aid in slowing.

60

OPERATION

Driving Through Water

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

1. Determine water depth and
current before entering
water.

2. Choose a crossing where the

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

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

3. Wet brakes may have reduced stopping ability. After leaving water,

test the brakes. Apply them lightly several times while driving
slowly. The friction will help dry out the pads.

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

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 67. Give special attention to engine
oil, transmission oil, demand drive fluid, rear gearcase oil, and all
grease fittings.

If your vehicle becomes immersed or is operated in water that
exceeds the floor level, take it to your dealer for service before
starting the engine. If it's impossible to bring the vehicle to your
dealer before starting the engine, perform the service outlined on
page 107, and take the vehicle to your dealer at the first opportunity.

Floor Level

61

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 rocks and fallen trees.
If unavoidable, use extreme caution and operate slowly.

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

62

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

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

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

63

OPERATION

Parking on an Incline

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

1. Place the transmission in PARK.

2. Turn the engine off.

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

64

OPERATION

Hauling Cargo

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

Never exceed the stated load capacity for this vehicle.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of the
operator, 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.

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

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

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

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

handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.

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

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

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

Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a passenger
to ride in the cargo box. A passenger must
always be seated in the passenger seat with
seat belt secured.

WARNING

65

OPERATION

Hauling Cargo

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

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

Always read and understand the load distribution warnings listed on
warning labels and in this manual. Never exceed the maximum capaci­ties specified for your vehicle. See page 120.

Belt Life

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

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 tow-

ing bracket.

2. Do not operate the vehicle faster than 10 mph (16 km/h) when tow­ing. Towing a trailer increases braking distance.

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

4. Attach a trailer to the trailer hitch bracket only. Do not attach a
trailer to any other location, which could result in loss of control of
the vehicle.

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

To t a l Tow e d

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 mph

(16 kph)

WARNING

66

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 arrestor that was tested and qualified to
be in accordance with the USFS standard 5100-1C. Federal law requires
that this spark arrestor 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 lower frame behind the driver’s
seat.

Electromagnetic Interference

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

tives 97/24/EC and 2004/108/EC.

67

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on
page 135.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

68

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

E Emission-related service (Failure to conduct this maintenance will
not void the emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

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

69

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Q

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist
on page 50.

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

Tires - Pre-Ride -

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

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

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

as needed

Coolant
(if applicable)

- Daily - Check level daily, change
coolant every 2 years

Headlamp/tail
lamp

- Daily - Check operation; apply
dielectric grease if replacing

XEAir filter,

main element

- Weekly - Inspect; replace as needed

X

Q

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

Battery 25 H Monthly 250 (400) Check terminals; clean; test

X Demand drive fluid 25 H Monthly 250 (400) Inspect level; change yearly
X Rear gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
X Main gearcase oil 25 H Monthly 250 (400) Inspect level; change yearly
X Transfer case oil 25 H Monthly 250 (400) Inspect level; change yearly

70

MAINTENANCE

Periodic Maintenance Chart

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

XEEngine breather

filter (if equipped)

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

X Engine oil change

(break-in)

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

filter change at one month

Q

E

Throttle cable/
ETC switch

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

replace if necessary

E Throttle body air

intake ducts/flange

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

ing/air leaks

X General

lubrication

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

cables, etc.

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

Q

Steering 50 H 6 M 500 (800) Lubricate

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

Cooling system
(if applicable)

50 H 6 M 500 (800) Inspect coolant strength

seasonally; pressure test
system yearly

Q

E

Fuel system 100 H 12 M 600 (1000) Check for leaks at tank cap,

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

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

X Engine oil change 100 H 6 M 1000 (1600) Perform a break-in oil change

at one month

X Oil filter change 100 H 6 M 1000 (1600) Replace with oil change

71

MAINTENANCE

Periodic Maintenance Chart

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

E Emission-Related Service

Q Have an authorized Polaris dealer perform these services

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

X Radiator

(if equipped)

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

surfaces

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

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

Q

Ignition timing 100 H 12 M 1000 (1600) Inspect

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

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

Q

Clutches (drive
and driven)

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

parts

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

Q

Front wheel
bearings

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

Q

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

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

Idle speed - Adjust as needed

Q

Toe adjustment - Inspect periodically; adjust

when parts are replaced

Headlight aim - Adjust as needed

72

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67, 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 Polaris Premium 4 Synthetic

0W40

Add to proper level on dipstick.
See page 75.

Brake Fluid DOT 4 Maintain level between fill lines.

See page 98.

Transmission Oil
(Main Gearcase)

Premium AGL Synthetic
Gearcase Lube

See page 80.

Transmission Oil
(Transfer Case)

Premium AGL Synthetic
Gearcase Lube

See page 78.

Demand Drive Fluid
(Front Gearcase)

Demand Drive LT Premium
Fluid

See page 82.

Rear Gearcase Oil Premium ATV Angle Drive

Fluid

See page 83.

Prop Shaft Polaris Premium U-Joint

Lube

Locate fittings and grease.

Control Arm Pivot
Bushings, Front/Rear

Polaris Premium all Season
Grease or grease
conforming to NLGI No. 2

Locate fittings and grease.

Stabilizer Bar Bushings,
Front/Rear

Polaris Premium all Season
Grease or grease
conforming to NLGI No. 2

Locate fittings and grease.

Prop Shaft

Grease Fitting

73

MAINTENANCE

Lubrication Recommendations

Stabilizer Bar

Bushings

Control Arm

Pivot Bushings

74

MAINTENANCE

Engine Oil

Always check and change the engine oil at the intervals outlined in the
Periodic Maintenance Chart beginning on page 67. Always change the
oil filter whenever changing oil.

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

Premium 4 Synthetic Oil

Polaris Premium 4 All Season Synthetic engine oil has been specially
formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high
performance, multi-viscosity oil designed to provide the ultimate in
lubrication performance and protection. See page 122 for the part num­bers of Polaris products.

Premium 4 possesses unsurpassed film strength over the widest possible
temperature range. It resists viscosity and frictional breakdown in ambi­ent temperatures from -40° to +120° F. (-40° to +49° C.). Its exceptional
frictional properties result in more efficient operation, more power out­put and lower fuel consumption.

Although Polaris Premium 4 is the only oil recommended for use in this
engine, use of any API certified "SH" oil is allowable as long as it's 0W-

40. Oil may need to be changed more frequently if Polaris Premium 4 is
not used. Follow the manufacturer's recommendations for ambient tem­perature operation.

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

engine damage. We recommend the use of Polaris Premium 4 All
Season synthetic oil or API certified "SH" oil, 0W-40. Never substitute
or mix oil brands. Use only 0W-40.

75

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67. Always use the recommended
engine oil.

Oil Check

The oil dipstick and fill tube is
located on the engine, behind the
passenger seat.

1. Position the vehicle on a level
surface.

2. Place the transmission in

PARK.

3. Remove both seats. Remove the

rear service panel. See page 29.

4. Lift the lever lock to remove the

dipstick. Wipe it dry with a clean
cloth.

5. Reinstall the dipstick completely,

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

6. Remove the dipstick and check

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

Tip: Due to the dipstick entry angle into

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

7. Reinstall the dipstick. Seat the

lever lock.

Dipstick

Safe

{

Safe

Range

Check Level

on Top Side

76

MAINTENANCE

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67. Always change the oil filter
whenever changing oil.

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

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

2. Start the engine. Allow it to idle

for two to three minutes. Stop
the engine.

3. Clean the area around the drain

plug.

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

4. Place a drain pan beneath engine

crankcase and remove the drain plug.

5. Allow the oil to drain completely.

6. Reinstall the sealing washer on the drain plug.

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

of burrs, nicks or scratches.

7. Reinstall the drain plug. Torque to 16 ft. lbs. (22 Nm).

Drain Plug

77

MAINTENANCE

Engine Oil

Oil and Filter Change

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

9. Using a clean dry cloth, clean the filter sealing surface on the crank­case.

10. Lubricate the o-ring on the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition.

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

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

13. Place the transmission in PARK. Apply the brakes.

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

15. Stop the engine. Inspect for leaks.

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

17. Dispose of used filter and oil properly.

78

MAINTENANCE

Gearcases

Transfer Case

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. Refer to the Gearcase
Specifications Chart on page 84 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug and level check plug are located on the left side of the
transfer case. The fluid level is sufficient when fluid flows out of the
check plug hole at step 4.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Remove the level check plug.

4. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.

5. Reinstall the level check plug. Torque to specification.

6. Reinstall the fill plug. Torque to specification.

Fill Plug

Level

Check

Plug

Drain Plug

79

MAINTENANCE

Gearcases

Transfer Case

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

6. Remove the level check plug.

7. Add the recommended fluid to the fill plug hole until it begins to
flow out of the check plug hole.

8. Reinstall the level check plug. Torque to specification.

9. Reinstall the fill plug. Torque to specification.

10. Check for leaks. Discard used fluid properly.

80

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. Refer to the Gearcase
Specifications Chart on page 84 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug is located on the left side
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 as

needed.

5. Reinstall the fill plug. Torque to

specification.

Fill Plug

81

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug.

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

6. Add the recommended fluid to the fill hole. Maintain the fluid level
at the bottom of the fill plug hole. Do not overfill.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Transfer Case

Drain Plug

Rear Gearcase

Drain Plug

Main Gearcase

Drain Plug

82

MAINTENANCE

Gearcases

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. Refer to the Gearcase
Specifications Chart on page 84 for recommended lubricants, capacities
and torque specifications.

Fluid Check

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

1. Position the vehicle on a
level surface.

2. Remove the fill plug. Check

the fluid level.

3. Add the recommended fluid

as needed.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

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

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

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

5. Reinstall the drain plug. Torque to specification.

6. Add the recommended fluid. Maintain the fluid level even with the

bottom thread of the fill plug hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Drain Plug

Fill Plug

83

MAINTENANCE

Gearcases

Rear Gearcase

Always check and change the fluid at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. Refer to the Gearcase
Specifications Chart on page 84 for recommended lubricants, capacities
and torque specifications.

Fluid Check

The fill plug is located on the
right side of the rear gearcase.
Maintain the fluid level even
with the bottom thread of the
fill plug hole.

1. Position the vehicle on a
level surface.

2. Remove the fill plug.

Check the fluid level.

3. Add the recommended

fluid as needed.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

The drain plug is located on the bottom right side of the rear gearcase.

1. Remove the fill plug.

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

3. Allow the fluid to drain completely.

4. Clean the drain plug. Reinstall the drain plug with a new o-ring.

Torque to specification.

5. Add the recommended fluid. Maintain the fluid level even with the

bottom thread of the fill plug hole.

6. Reinstall the fill plug. Torque to specification.

7. Check for leaks. Discard used fluid properly.

Fill Plug

Drain Plug

84

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See
page 122 for the part numbers of Polaris products.

Gearcase Lubricant Capacity Fill Plug

To r q u e

Drain Plug/

Level Check

Plug Torque

Transmission

(Main Gearcase)

Premium AGL

Synthetic

Gearcase Fluid

24 oz.

(710 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Transmission

(Transfer Case)

Premium AGL

Synthetic

Gearcase Fluid

14 oz.

(414 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

Demand Drive Unit

(Front Gearcase)

Demand Drive LT

Premium Fluid

6.75 oz.
(200 ml)

8-10 ft. lbs.

(11-13.6 Nm)

11 ft. lbs.

(15 Nm)

Rear Gearcase Premium ATV

Angle Drive Fluid

26 oz.

(769 ml)

40-50 ft. lbs.

(54-68 Nm)

30-45 in. lbs.

(3-5 Nm)

85

MAINTENANCE

Fuses

If the engine stops or will not start, if the power steering stops working
(if equipped), 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 above the
power steering unit. One spare 20 amp
fuse is provided in the fuse box.

1. Remove the fuse box cover.

2. Remove the suspect fuse from the

fuse panel. If the fuse is blown,
install a new fuse with the same
amperage rating.

3. Reinstall the fuse box cover.

Tip: The 120 ohm resistor (if equipped) is

used by your Polaris dealer for power
steering diagnostics.

Spark Plugs

Spark Plug Gap/Torque

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

damage. Always use Polaris-recommended spark plugs. Refer to the
specifications section beginning on page 120.

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 86.

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

Fuse Feature Supported

15A Accessories, 12V Power Receptacle
15A Electronic Fuel Injection
15A Engine Control Module
15A Lights
20A Main Fuse - Ignition, Instrument Cluster
30A Power Steering (if equipped)

Electrode Gap New Plug Torque Used Plug Torque

.035" (.9 mm) 18 ft. lbs.

(24 Nm)

18 ft. lbs.

(24 Nm)

86

MAINTENANCE

Spark Plugs

Spark Plug Condition

Normal Plug

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

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

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

Wet Fouled Plug

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

Spark Plug Removal and Replacement

1. Remove both seats.

2. Remove the rear service
panel. See page 29.

3. Remove the spark plug cap.

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

5. Reverse the procedure for
spark plug installation.
Torque to specification. See
page 85.

Spark Plugs

87

MAINTENANCE

Cooling System

Operation

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

As coolant operating temperature increases, the expanding (heated)
excess coolant is forced out of the radiator, past the pressure cap, and
into the overflow bottle. As engine coolant temperature decreases, the
contracting (cooled) coolant is drawn back up from the tank, past the
pressure cap, and into the radiator.

Tip: Some coolant level drop on new vehicles is normal as the system is purging

itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added. Polaris recommends the
use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of
high quality aluminum compatible anti-freeze/coolant and distilled
water. Polaris Premium 60/40 is already premixed and ready to use. Do
not dilute with water. See page 122 for the part numbers of Polaris prod­ucts.

Tip: Always follow the manufacturer's mixing recommendations for the freeze

protection required in your area.

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

88

MAINTENANCE

Cooling System

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 67. 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 high­pressure system is not recommended.

89

MAINTENANCE

Cooling System

Coolant Level

Always check and change
the coolant at the intervals
outlined in the Periodic
Maintenance Chart begin­ning on page 67. 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. Remove the hood. See

page 31.

3. View the coolant level in the overflow bottle.

4. If the coolant level is below the safe operating range, remove the

cap and use a funnel to add coolant through the 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. Have the cooling system inspected by
your Polaris dealer.

Coolant

Overflow

Bottle

Radiator

Cap

90

MAINTENANCE

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 67. 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.

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.

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.

1. Remove the hood. See page 31.

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: Use of a non-standard pressure cap will not allow the recovery system to

function properly. See your dealer for the correct replacement part.

91

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. Extensive engineering and testing has been conducted to
ensure the safety of this product. However, as the owner, you have the following
responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See 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 place during operation.

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.).

WARNING

92

MAINTENANCE

Polaris Variable Transmission (PVT) System

PVT Drying

Before washing the vehicle, locate the PVT outlet duct under the right
rear wheel well. Avoid spraying water directly toward the duct when
washing the vehicle from the rear. See page 114.

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

1. Remove the seats. See page 29.

2. Loosen the lower screws that secure the clutch cover.

3. Allow the water to drain.

4. Tighten the screws.

5. Place the transmission in PARK. Apply the brakes.

6. Start the engine.

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

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

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

10. Take the vehicle to your dealer for service as soon as possible.

93

MAINTENANCE

Filter Systems

Air Filter

Always change the air filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67.

1. Access the air box from
behind the left rear wheel.

2. Remove the air box cover

and inspect the gasket. It
should adhere tightly to the
cover around the entire
edge.

3. Remove the air filter.

4. Install a new filter if

needed. Do not attempt to
clean the air filter. Apply a
small amount of general
purpose grease to the seal­ing edges of the filter
before installing.

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

into a suitable container.

Air Box Cover

Air Filter

Gasket

94

MAINTENANCE

Spark Arrestor

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

Do not perform clean-out immediately after the engine has been run, as the
exhaust system becomes very hot. Serious burns could result from contact with
the exhaust components. Allow components to cool sufficiently before
proceeding.

Wear eye protection and gloves.
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.

Periodically clean the spark arrestor to remove accumulated carbon.

1. Remove the retaining
screw and remove the
arrestor from the end
of the muffler.

2. Use a non-synthetic
brush to clean the
arrestor screen. A syn­thetic brush may melt
if components are
warm. If necessary,
blow debris from the
screen with com­pressed air.

3. Inspect the screen for

wear and damage.
Replace a worn or
damaged screen.

4. Reinstall the arrestor.

Torque screws to 5-7 ft. lbs. (7-9 Nm).

WARNING

Arrestor

Retaining

Screw

Screen

Muffler

95

MAINTENANCE

Throttle System

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

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

Immediately contact your dealer for service if throttle problems arise.
Always check the pedal for free movement and return before starting the engine

and occasionally during operation.

Throttle Freeplay

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

Check the throttle pedal freeplay
at the intervals outlined in the
Periodic Maintenance Chart
beginning on page 67. Adjust the
freeplay if necessary.

Throttle Freeplay Inspection

1. Place the transmission in PARK.

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

3. Measure the distance the throttle pedal moves before the engine
begins to pick up speed. Freeplay should be 1/16 to 1/8 inches (1.5­3 mm).

WARNING

Throttle

Pedal

96

MAINTENANCE

Throttle System

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not
satisfactory, please see your Polaris dealer for adjustment.

Throttle Freeplay Adjustment

1. Remove both seats. Remove
the rear service panel. See
page 29.

2. Locate the throttle cable

adjuster at the throttle body.

3. Slide the cable adjuster boot

off the cable adjuster.

4. Using a 10 mm open-end

wrench, loosen the adjustment
jam nut.

5. Using an 8 mm open-end

wrench, move the cable
adjuster until 1/16" to 1/8"
(1.5-3 mm) of freeplay is
achieved at the throttle pedal.
See page 95. While adjusting,
lightly flip the throttle pedal
up and down.

6. Tighten the jam nut.

7. Apply a small amount of

grease to the inside of the
boot and slide it over the
cable adjuster to its original
position.

Adjuster

Boot

Adjuster

Jam Nut