Polaris RZR XP 1000 EPS High Lifter Edition Owner's Manual

RZR® XP 1000 EPS

High Lifter Edition

Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions and safety

precautions in this manual and on all product labels.

Failure to follow the safety precautions

could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals

known to the State of California to cause cancer, birth defects

or other reproductive harm.

For videos and more information

about a safe riding experience with

your Polaris vehicle, scan this QR

code with your smartphone.

1

WELCOME

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

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

We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we’ve ever
produced.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Review the
safety DVD that came with your vehicle. Polaris also recommends that
all drivers take the ROHVA safety e-course and a ROHVA hands-on
safety training course (www.rohva.org).

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

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

• Snowmobiles • RZR® sport vehicles

• All-terrain vehicles (ATVs) • GEM® electric vehicles

• Low emission vehicles (LEVs) • VICTORY® motorcycles

• RANGER® utility vehicles • INDIAN® motorcycles

•BRUTUS® work vehicles • POLARIS POWER® generators

• SLINGSHOT® three wheel
motorcycles

• POLARIS DEFENSE® combat
vehicles

2

POLARIS® and RZR® are trademarks of POLARIS Industries Inc.
Copyright 2015 Polaris Industries Inc. All information contained within this publication

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

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

Printed in U.S.A.
2016 RZR XP 1000 EPS High Lifter Edition Owner’s Manual
P/N 9926601

For a closer look at your RZR’s features
and recommended maintenance, scan
this QR code with your smartphone.

3

TABLE OF CONTENTS

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

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

Features and Controls. . . . . . . . . . . . . . . . . . . 25

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

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Emission Control Systems . . . . . . . . . . . . . . . 78

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 130

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 131

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 132

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 144

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

4

INTRODUCTION

The RZR is an off-road vehicle. Familiarize yourself with all laws and
regulations concerning the operation of this vehicle in your area.

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

The safety alert symbol indicates a potential personal injury ha zard.

DANGER

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

WARNING

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

CAUTION

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

NOTICE

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

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

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

5

INTRODUCTION

Failure to 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 and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your local
POLARIS dealer. Understand all safety warnings, precaution s and operating
procedures before operating the vehicle. Keep this manual with the vehicle.

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

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

• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.

• Always wear a seat belt when riding in this vehicle. Always wear a helmet, eye
protection, gloves, long-sleeve shirt, long pants and over-the-ankle boots.

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

• 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.

European Vibration and Noise

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

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

indicated by the test procedure(s).
The uncertainty of vibration exposure measurement is dependent on many

factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

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

Safety Training

Safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding this vehicle
to take a training course.

ROHVA (Recreational Off-Highway Vehicle Association) provides both
an online safety e-course and a hands-on safety course. To access this
valuable training, visit www.rohva.org.

Your POLARIS vehicle is considered an off-road vehicle. Familiarize
yourself with all laws and regulations concerning the operation of this
vehicle in your area.

W e strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.

For more information about recreational off-road vehicle safety in
the United States, visit www.rohva.org or call POLARIS at 1-800­342-3764.

8

SAFETY

Safe Riding Gear

The driver and all passengers must wear helmet, eye protection, gloves,
long-sleeve shirt, long pants, over-the-ankle boots and seat belt at all
times. Protective gear reduces the chance of injury .

Helmet

W e aring 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.

E

4

051039

0006.31

Helmet

Eye Protection

Gloves

Over-the-Ankle

Boots

Long Pants

Long

Sleeves

9

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this 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 over-the-ankle boots for support and protect ion. Never ride
a POLARIS vehicle with bare feet or sandals.

Clothing

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

Rider Comfort

Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the driver and passenger cab
area. The condition occurs most frequently when a vehicle is being
operated in high ambient temperatures at low speeds and/or high load
conditions for an extended period of time. The use of certain
windshield, roof and/or cab systems may contribute to this condition by
restricting airflow. Any discomfort due to heat buildup in this area can
be minimized by wearing proper riding apparel and by varying speeds to
increase airflow.

10

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.

Proper Use Warning

WARNING

Require Proper Use of Your Vehicle
Do your part to prevent injuries:

• Do not allow careless or reckless driving.

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

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

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

• Do not exceed seating capacity: 1 passenger

Proper Use

Warning

Seat Belt

Warning

Drive Responsibly Warning

Riders

Warning

Payload
Warning

11

SAFETY

Safety Labels and Locations

Drive Responsibly Warning

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even
from a stop.

• Plan for hills, rough terrain, ruts and other
changes in traction and terrain.

• Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

7179761

Payload Warning

WARNING

Riders Warning

Be Sure Riders Pay Attention an d Pla n Ahead

If you think or feel the vehicle may tip or roll, reduce your risk of injury:

• Keep a firm grip on the steering wheel or hand holds and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

7179762

Seat Belt Warning

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belts.

• Wear an approved helmet and protective gear.

• ALWAYS use cab nets and/or doors.

• Each rider must be able to sit with back against seat, feet flat on the floor, and
hands on steering wheel or hand holds. Stay completely inside the vehicle.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA
TRAINING (rohva.org).

7179499

RZR Never Exceed If Total Payload Exceeds
XP 1000 High Lifter 68 MPH (109 km/h) 430 lbs. (195 kg)

Rollovers have caused

severe injuries and death,

even on flat, open areas.

12

SAFETY

Safety Labels and Locations

Fuel Transport Warning

WARNING

Before transporting flammable liquids
in this vehicle, ALWAYS read your
Owner’s Manual.

• Always use containers designed for
off-road vehicles.

• Inspect containers for wear, cracks
and leaks before each ride.

• Always make sure containers are
firmly secured to avoid spills and
damage.

Failure to follow proper instructions
could lead to burn injury and other
potential fire hazards.

7182513

Load/Passenger/Tire Pressure Warning

WARNING

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

• Never carry passengers in cargo box.

WARNING

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

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

• Overloading or carrying tall, off-center, or unsecured loads will increase your

risk of losing control. Loads should be centered and carried as low as
possible in box.

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

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

RZR XP 1000

High Lifter

MAXIMUM CARGO BOX LOAD 300 lbs.

(136 kg)

TIRE PRESSURE IN PSI (KPa) FRONT 18 (124)

REAR 18 (124)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, PASSENGERS,
CARGO AND ACCESSORIES

740 lbs.

(336 kg)

Read Operation and Maintenance Manual for more detailed loading information.

Load/Passenger/Tire Pressure

Warning

Fuel Transport Warning

13

SAFETY

Safety Labels and Locations

Belt Debris Warning

WARNING

Improper service or maintenance of this
PVT system can result in vehicle
damage, SEVERE INJURY or DEATH.

Always look for and remove debris
inside and around the clutch and vent
system when replacing the belt.

Read owner’s manual or see authorized
POLARIS dealer.

7177469

Air Box Caution

CAUTION

Use a Polaris approved air filter. The
use of a non-Polaris approved air filter
may cause engine damage. Before
installing filter, ensure there is no dirt or
debris in the clean side of the intake
tube. The air filter must be properly
seated before the lid is reinstalled.
Please reference your owner’s manual
for additional information regarding air
filter service.

Belt Debris Warning

Air Box Caution

14

SAFETY

Safety W arnings

Failure to operate this vehicle properly can result in a collision, loss of control,
accident or rollover, which may result in serious injury or death. Heed all safety
warnings outlined in this section of the owner’s manual and in the safety DVD
provided with your vehicle. 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. Take a training course and
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.

Operator Restrictions/Age Restrictions

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

Never operate with a passenger under the age of

12. All riders must be able to sit with backs

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

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

15

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 perform the pre-ride inspection before
each use of your vehicle to make sure it's in
safe operating condition. See page 50.

Always follow the inspection and maintenance
procedures and schedules described in this
owner’s manual. See page 79.

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 all passengers must always wear
a helmet, eye protection, gloves, long-sleeve
shirt, long pants and over-the-ankle boots.

Seat Belts

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

All riders must wear seat belts at all times.

Cab Doors

Riding in this vehicle without closed and latched cab doors increases the risk of
serious injury or death in the event of an accident or rollover. Always make sure
all cab doors are closed and latched while riding in this vehicle. Cab doors are
NOT intended to be used as arm rests. Always keep hands and feet inside the

vehicle at all times.

16

SAFETY

Safety Warnings

Carrying Multiple Passengers (RZR XP)

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.

A passenger must always be seated in a passenger seat
with seat belt secured. Carrying more than one passenger
in a 2-seat vehicle can affect the operator’s ability to steer
and operate the controls, which increases the risk of loss of
control and accident or rollover.

Never carry more than one passenger in a 2-seat vehicle.

Operating With a Load on the Vehicle

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

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When more passenger weight is added, cargo weight may need to
be reduced accordingly.

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

Always follow these guidelines:

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

Passenger and/or cargo exceeds half the
maximum weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when
operating.

Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing

17

SAFETY

Safety Warnings

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 a passenger seat with seat
belt secured.

Operating on Pavement

This vehicle's tires are designed for off-road use only, not for use on pavement.
Operating this vehicle on paved surfaces (including sidewalks, paths, parking
lots and driveways) may adversely affect the handling of the vehicle and may
increase the risk of loss of control and accident or rollover. Avoid operating the
vehicle on pavement. If it's unavoidable, travel slowly, travel short distances and
avoid 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 (unless designated for
off-highway use).

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
experience and your passengers’ skills and
experience.

18

SAFETY

Safety Warnings

Turning Improperly

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

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.

Jumps and Stunts

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

Improper Hill Climbing

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

58.

Descending Hills Improperly

Improperly descending a hill could cause
loss of control or rollover. Always follow
proper procedures for traveling down hills
as described in this owner’s manual. See
page 59.

19

SAFETY

Safety Warnings

Crossing Hillsides

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

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

Stalling While Climbing a Hill

St alling or rolling backwards while climbing a
hill could cause a rollover. 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
rollover.

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

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

20

SAFETY

Safety Warnings

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 rollover.

Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in this owner's manual and on safety labels.

Skidding or Sliding

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

Skidding or sliding due to loss of traction can
cause loss of control or rollover (if tires regain
traction unexpectedly). Always follow proper procedures for operating on
slippery surfaces as described in this owner's manual. See page 57.

Operating Over Obstacles

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

Before operating in a new area, check
for obstacles. Never attempt to operate
over large obstacles such as large
rocks or fallen trees. Always follow the
proper procedures outlined in this
manual when operating over obstacles.
See page 61.

21

SAFETY

Safety Warnings

Operating Through Water

Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, rollover or accident. Never operate
in fast-flowing water or in water that
exceeds the floor level of the vehicle.

Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 60.

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.

Operating on Frozen Bodies of Water

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

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

Operating a Damaged Vehicle

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

22

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Always follow the instructions in this
owner’s manual for carrying cargo. See
page 64.

• Never exceed the stated load capacity for
this vehicle. See page 12.

• Cargo should be properly distributed and
securely attached. See page 64.

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

Refueling

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

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

• Always use an approved gasoline container to store fuel and remove the
container from the vehicle before filling to avoid fuel ignition due to electrical
static discharge.

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

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

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

23

SAFETY

Safety Warnings

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, to
avoid debris build-up around the exhaust system.

Unauthorized Use of the Vehicle

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

24

SAFETY

Safety Warnings

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 any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.

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

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

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

25

FEATURES AND CONTROLS

Component Locations

Cab

Doors

Fuel T ank

Cap

Cargo

Box

Passenger
Hand Hold

ROPS Frame

Gear Selector

Throttle

Pedal

Brake
Pedal

Cargo Box Tie-Down

Points (4 corners)

Winch

Tow Loop

Snorkels

26

FEATURES AND CONTROLS

Switches

Auxiliary Outlets

This vehicle is equipped with one 12-volt accessory outlet. Use the
outlet to power an auxiliary light or other optional accessories. For
service, the dash outlet connection is under the dash.

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.

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.

Light Switch

AWD Switch

12V Accessory Outlet

Ignition Switch

Winch Switch

Remote Winch

Switch

27

FEATURES AND CONTROLS

Switches

Headlight Switch

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

Press the top of the rocker switch for high beam.
Move the rocker switch to the center position for
low beam. Press the bottom of the rocker switch
to turn headlights off.

If the headlight switch is ON when the ignition switch is turned off, the
lights will remain on for approximately 30 seconds.

All Wheel Drive (AWD) Switch

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 38 for AWD operating instructions.

Winch Switch

Press the top of the rocker switch to spool line
out from the winch. Press the bottom of the
rocker switch to spool line in to the winch.
Move the rocker switch to the center position
to stop spooling.

Remote Winch Switch

Pull the remote winch switch
and cable out from the dash
storage area. Press and hold the
left side of the switch to spool
line out from the winch. Press
and hold the right side of the
switch to spool line in to the
winch. Release the switch and it
returns to the center “OFF”
position to stop spooling.

HIGH

LOW

OFF

AWD

2WD

OUT

IN

OFF

OUT

IN

OFF

28

FEATURES AND CONTROLS

Seats

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

Seat Adjustments

On seats equipped with an adjustment lever under the front edge of the
seat, pull the lever to the left. Slide the seat forward or rearward to the
desired position. Release the lever. The seat will lock into the new
position.

For other seat styles, 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

Rear Seat Latch

29

FEATURES AND CONTROLS

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 post mounting hole, adapter bushing
hole, both post adjustment holes and lastly through the remaining
bushing hole and post mounting hole.

5. Reinstall the retainer to the pin.

A

d

j

u

s

t

m

e

n

t

P

o

s

i

t

i

o

n

H

o

l

e

s

Post Mounting

Holes

Adjustment

Pin

Pin

Retainer

Adapter

Bushing

30

FEATURES AND CONTROLS

Hood

Remove the hood to access the radiator pressure cap and coolant
overflow bottle.

1. Turn the hood fasteners 1/4 turn.

2. Grasp the upper hood edge and pull upward to disengage the
fasteners.

3. Pivot the hood forward and lift upward to disengage the lower hood
hooks.

4. Lift the hood away from the vehicle.

Hood Fasteners

Pressure Cap

Overflow Bottle

31

FEATURES AND CONTROLS

Fuel Cap

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

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

Service Access Panels

Engine Access Panel

The engine access panel is
located behind the seats on
the frame of the vehicle.
Remove the seats and remove
the access panel to reach
serviceable engine
components.

Cargo Box Access Panel

The cargo box access panel
is located on the floor of the
cargo box. Remove the panel
to access the engine oil fill
cap, spark plugs and air
filter.

Fuel Cap

32

FEATURES AND CONTROLS

Seat Belts

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

3-Point Seat Belt

To wear the 3-point 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. Pull up on the
strap to tighten.

3. Press the red release latch on the buckle to release the seat belt.

Seat Belt Height Adjuster (if equipped)

A breakthrough in comfort, the seat belt height
adjuster reduces neck rub and works as a
shock absorber for your shoulder. The height
adjuster consists of an adjuster (1) and a rail
(2). (3) designates the adjustment zone.

HOW TO ADJUST THE HEIGHT OF YOUR SEAT
BELT FOR DESIRED COMFORT AND PROPER

FIT

continued on next page

1

2

3

Proper location
of shoulder belt

Wrong Wrong

33

FEATURES AND CONTROLS

Seat Belts

Seat Belt Height Adjuster (if equipped)

STEP 1

Stretch the seat belt height adjuster toward the
front of the vehicle.

STEP 2

While continuing to stretch the seat belt
height adjuster, slide the adjuster up or down,
rocking it side to side if necessary, until you
reach the desired height. This may require
both hands. Do not attempt to adjust while
vehicle is in motion.

NOTE: Adjustment becomes easier with
repeated use.

CLEANING INSTRUCTIONS: The seat belt height adjuster can be
cleaned with water.

STEP 1

STEP 2

34

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. Rinse the entire length of the belt webbing. Use a garden
hose to flush out the retractor and latch housings regularly.

Retractor

Housing

Latch Housings

35

FEATURES AND CONTROLS

Cab Doors

This vehicle is equipped with cab doors. Riding in this vehicle without
closed and latched cab doors increases the risk of serious injury or death
in the event of an accident or rollover. Always make sure all cab doors
are closed and latched when riding in this vehicle.

Always inspect doors and latches for wear and damage before each use
of the vehicle.

Promptly replace any worn or damaged parts with new parts available
from your authorized POLARIS dealer.

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

transmission function. Your POLARIS dealer can assist in resolving 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

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

• Operating in rough terrain or over obstacles

• Operating in mud or other high-load conditions

• Towing heavy loads

• Loading the vehicle onto a trailer

Gear Selector

36

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.

Electronic Power Steering (EPS)

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.

The EPS warning indicator briefly illuminates when the key is turned to
the ON position. See page 40.

To conserve battery power, the EPS will shut down 5 minutes after the
engine is stopped if the key remains in the ON position. The EPS
warning indicator will illuminate to indicate the EPS has shut down.

If the light remains on after starting the engine, the EPS system is
inoperative. See your authorized POLARIS dealer for service.

Adjustment Lever

37

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.

Tip: If the throttle pedal and brake pedal are applied simultaneously, engine

power may be limited.

Rollover Protective Structure (ROPS)

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

No device can assure occupant
protection in the event of a r ollover.

When used with seat belts and cab
nets or doors, the ROPS helps
prevent occupants from being
ejected from the vehicle. Always
follow all safe operating practices
outlined in this manual to avoid
vehicle rollover.

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

Throttle Pedal

Brake Pedal

ROPS Label

(on ROPS or on

passenger hip bar)

38

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 4X4 indicator in the
instrument cluster 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.

AWD

2WD

39

FEATURES AND CONTROLS

Instrument Cluster

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

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

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

the instrument cluster.

Speedometer

The speedometer displays vehicle speed in either miles per hour (MPH)
or kilometers per hour (km/h). See page 43.

Mode Button

Use the MODE button to toggle through mode options. See page 43 for
operation of the modes.

Rider Information

Center

Speedometer

Indicator Lamps

MODE
Button

40

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle
Speed

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

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

Over
Temperature

This lamp illuminates to indicate an overheated
engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.

EPS Warning This indicator illuminates briefly when the ke y is

turned to the ON position. If the light remains on, the
EPS system is inoperative. Your POLARIS dealer can
assist.

Neutral This lamp illuminates when the transmission is in

neutral and the ignition key is in the ON position.

High Beam This lamp illuminates when the headlamp switch is

set to high beam.

Helmet/Seat
Belt

The lamp is a reminder to the operator to ensure all
riders are wearing helmets and seat belts before
operating. The driver's seat belt is equipped with a
seat belt interlock. Vehicle speed will be limited to 15
MPH (24 km/h) if the seat belt is not secured.

Check Engine This indicator appears if an EFI-related fault occurs.

Do not operate the vehicle if this warning appears.
Serious engine damage could result. Your POLARIS
dealer can assist.

41

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 44.

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

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

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

1

2

65

4

7

3

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

2. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.

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

fuel sensor circuit. Your POLARIS dealer can assist.

3. Information Display Area - This area displays odometer, trip
meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the
vehicle is operating at an RPM too low to keep the battery charged.
It may also occur when the engine is at id le and hig h electrical load
(lights, cooling fan, accessories) is applied. Drive at a higher RPM
or recharge the battery to clear the warning.

5. Clock - The clock displays time in a 12-hour or 24-hour format. See
page 44 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator
that the preset service interval has been reached. Your POLARIS
dealer can provide scheduled maintenance. See page 44 for reset­ting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is
engaged (switch is on 4X4).

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

Display Units (Standard/Metric)

The display can be changed to show either
standard or metric units of measurement for
each of the following settings.

Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key

on. The gauge display the mode that was displayed prior to setting the
units.

1. Turn the key to the OFF position.

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

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

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

5. Repeat the procedure to change remaining display settings.

Standard Display Metric Display

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

MODE

Button

44

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

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

discharged.

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

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

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

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

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.

6. Turn the key to the OFF position.

45

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

Engine Temperature Mode

This mode displays current temperature of the coolant.

Battery Voltage Mode

This mode displays current system voltage level.

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.

46

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Programmable Service Interval

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

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

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to

advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

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

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

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

Inactive codes are stored in the history of the unit.

47

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

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

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

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

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

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

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

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

6. Your authorized POLARIS dealer can provide code details and

diagnosis.

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

48

OPERATION

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

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. Clutch and drive belt break-in periods vary depending on
operating conditions. See page 49.

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 improper oils may cause serious engine damage.
POLARIS Premium 4 Synthetic Oil is specifically formulated for your
4-cycle engine.

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 87. 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.

WARNING

49

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

7. Carry only light loads.

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

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

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. If a belt fails, always clean any debris from the
duct and from the engine compartment.

Standard Break-In

Drive at slower speeds for the first 50 miles (80 km) of operation. Carry
only light loads. Avoid aggressive acceleration, high-speed operation
and prolonged operation at a specific RPM during this period.

Sand/Dune/Mud Break-In

Drive in low gear for the first 5 miles (8 km) of operation. Avoid
prolonged low speed operation at high throttle. Avoid aggressive
acceleration, high-speed operation and prolonged operation at a specific
RPM during this 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 37

108
Brake pads Inspect, replace if damaged 109
Brake fluid Ensure proper level 110
Front suspension Inspect, lubricate if necessary 84
Rear suspension Inspect, lubricate if necessary 84
Steering Ensure free operation 120
Tires Inspect condition and pressure 12

115
Wheels/fasteners Inspect, ensure fastener tightness 115
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 42

87
Coolant level Ensure proper level 98-99
Coolant hoses Inspect for leaks ­Throttle Ensure proper operation ­Indicator lights/switches Ensure proper operation 26-27
Headlights Check operation ­Brake light/taillight Check operation ­Seat latches Push down on both seat backs to

ensure the latches are secure

28

Seat belts Check length of belt for damage,

check latches for proper operation

32

Cab doors Check doors and latches for wear or

damage.

35

Sp ark arrester Inspect and clean as needed, replace

if damaged

106

51

OPERATION

Safe Operation Practices

1. Visit the Recreational Off-Highway Vehicle Association web site
(rohva.org) and take the free on-line training course. Complete the
New Operator Driving Procedures outlined on pages 54-55.

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 one passenger in a 2-seat 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

conditions. 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

vehicle.

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 rollover 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 unless you have

first verified that the ice is sufficiently thick to support the weight
and moving force of the vehicle, you and your passengers, and your
cargo, together with any other vehicles in your party.

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

combustible 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. Always make sure all

cab doors are closed and latched when riding in this vehicle.

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.

4. Slowly release the brake pedal and make sure the transmission is in

PARK before exiting the vehicle.

Braking

1. Release the throttle pedal completely.

Tip: 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.

3. Practice starting and stopping (using the brakes) until you're famil-

iar 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. Slowly release the brake pedal and make sure the transmission is in

PARK before exiting the vehicle.

5. 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. Visit the Recreational Off-Highway Vehicle Association web site

(rohva.org) and take the free on-line training course. Hands-on
training is also available through ROHVA.

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

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

experience with this vehicle.

5. Do not carry cargo during this period.

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

vehicle operation and handling.

7. The driver and all passengers must wear helmet, eye protection,

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat
belt at all times.

8. Always make sure all cab doors are closed and latched when riding

in this vehicle.

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

10. Place the transmission in PARK.

11. Start the engine.

55

OPERATION

New Operator Driving Procedures

12. Apply the brakes and shift into low gear.

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

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

15. 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.

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 Passengers

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

2. Perform the pre-ride

inspection. See page

50.

3. Do not carry more

than one passenger in
a 2-seat vehicle.
Additional passengers
can affect the operator’s ability to steer and operate the controls.

4. Make sure all passengers are at least 12 years of age. All riders must

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

5. The driver and all passengers must wear helmet, eye protection,

gloves, long-sleeve shirt, long pants, over-the-ankle boots and seat
belt at all times. See page 8.

6. Always make sure all cab doors are closed and latched when riding

in this vehicle.

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

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

your passengers’ skills and operating conditions. Avoid unexpected
or aggressive maneuvers that could cause discomfort or injury to a
passenger.

9. Vehicle handling may change with passengers and/or cargo on

board. Allow more time and distance for braking.

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

and in this manual.

57

OPERATION

Driving on Slippery Surfaces

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

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.

Sideways

skid

Turn in

direction of

skid

58

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always check the
terrain carefully
before ascending a
hill. Never drive on
hills with excessively
slippery or loose
surfaces.

2. Avoid excessively

steep hills. If
ascending a steeper
grade is unavoidable,
engage all-wheel
drive before ascending.

3. Drive straight uphill.

4. Proceed at a steady rate of speed and throttle opening. Never open

the throttle suddenly.

5. Avoid unnecessary changes in speed or direction.

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

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

7. 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.

59

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Drive slowly and use extreme caution.

3. If the vehicle begins to roll over, or if it feels as if it may roll over,
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 excessively steep

hills.

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

3. Always check the terrain
carefully before
descending a hill. Never
drive on hills with
excessively slippery or
loose surfaces.

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,
rollover 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. Avoid applying
brake and throttle at the same time.

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 79. 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, service is required before starting the engine.
Your POLARIS dealer can provide this service. If it's impossible to
bring the vehicle in before starting the engine, perform the service
outlined on page 119, and take the vehicle in for service 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 large rocks and fallen
trees. If unavoidable, use extreme caution and operate slowly.

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

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
precautions:

1. Apply the brakes.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Slowly release the brake pedal and make sure the transmission is in
PARK before exiting the vehicle.

5. Block the rear wheels on the downhill side.

64

OPERATION

Hauling Cargo

Overloading the vehicle or carrying 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, passengers, accessories and loads in the rack or box. Th e 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 cargo. 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. \

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 a
rollover.

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) 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 a
passenger seat with seat belt secured.

WARNING

65

OPERATION

Hauling Cargo

Your POLARIS vehicle has been designed to carry a specific capacity.
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 130.

Belt Life

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

• when hauling or towing heavy cargo.

• when consistently operating at speeds less than 35 MPH (56 km/h) in

hard-pulling terrain, such as mud, rocks or sand/dune environments.

66

OPERATION

Towing

Towing improperly can alter vehicle handling and may cause loss of control or
brake instability.

The tow loop on the rear of the
vehicle is provided for recovery
use ONLY. Tow a vehicle ONLY
of equal or lesser size and weight.

When towing a disabled RZR
vehicle, place the disabled
vehicle's transmission in neutral.
Do not operate the vehicle faster
than 10 MPH (16 km/h) when
towing.

Towing a RZR

Towing this vehicle is not recommended. Always transport the vehicle
on a trailer or flatbed with all four wheels off the ground. See page 129.

If towing a disabled vehicle is unavoidable, place the disabled vehicle’ s
transmission in neutral. Tow the shortest distance possible. Do not
operate faster than 10 MPH (16 km/h).

WARNING

Tow Loop

67

WINCH GUIDE

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

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

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

Winch Safety Precautions

1. Read all sections of this manual.

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

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

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

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

6. Never attempt to “jerk” a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 76.

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

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

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

WARNING

68

WINCH GUIDE

Winch Safety Precautions

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

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

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

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

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

B. If stacking occurs, stop winching. Follow step 15 on page 74 to feed

and rewind the cable evenly before continuing the winch operation.

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

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

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

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

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

69

WINCH GUIDE

Winch Safety Precautions

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

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

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

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

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

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

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

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

70

WINCH GUIDE

Winch Operation

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

Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

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

Each winching situation is unique.

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

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

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

• Always remember that your winch is very powerful.

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

1. Always inspect the vehicle, winch, winch cable and winch controls
for any signs of damage or parts in need of repair or replacement
before each use. Pay particular attention to the first 3 feet (1 meter)

of winch cable if the winch is being used (or has been used) for lift­ing an accessory plow assembly. Promptly replace any worn or

damaged cable.

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

3. Always apply your

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

WARNING

Hook Strap

71

WINCH GUIDE

Winch Operation

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

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

A. Attach the hook itself onto the

load or use a tow strap or chain
to secure the load to the winch
cable.

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

stretch.

WARNING! Never use a recovery strap when winching due to the excessive
energy that can be released if the winch cable breaks. This can result in
SEVERE INJURY or DEATH. See the Shock Loading section on p a g e 76 .

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

winch cable and may result in winch cable failure.

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

C. If possible, keep the winch cable aligned with the centerline of the

winching vehicle. This will help the spooling of the winch cable and
reduce the load on the fairlead.

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

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

E. Before operating the winch, be sure

that the safety latch on the winch
cable hook is fully seated when the
load is attached.

F. Never operate your winch with a

damaged hook or latch. Always
replace damaged parts before using
the winch.

NO YES

NO

YES

72

WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

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

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

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

A. In order to absorb energy that could be released by a winch cable

failure, always place a “damper” on the winch cable. A damper can be
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.

B. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

C. On a long pull, it may be necessary to stop winching so that the

damper can be repositioned to the new mid-point of the winch cable.
Always release the tension on the winch cable before repositioning the
damper.

D. Avoid being directly in line with the winch cable whenever possible.

Also, never permit others to stand near or in line with the winch cable
during winch operation.

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

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

73

WINCH GUIDE

Winch Operation

11. The ONLY time a winch-equipped vehicle should be moving when
using the winch is when that vehicle itself is stuck. The winch­equipped vehicle should NEVER be in motion to “shock” load the
winch cable in an attempt to move a second stuck vehicle. See the
Shock Loading section on page 76. For your safety, always follow
these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch

cable.

B. Align the winch cable as close as possible to the winching vehicle’s

centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle gear to propel the stuck vehicle in the

direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

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

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

74

WINCH GUIDE

Winch Operation

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

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

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

kg) of tension using the hook strap.

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

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

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

between lower layers of winch cable.

75

WINCH GUIDE

Winch Cable Care

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

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

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

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

or kinked winch cable.

A. A kinked winch cable made of

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

B. A kinked winch cable made of

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

C. A winch cable made of

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

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

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

A

B

C

76

WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic,

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

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

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

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

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

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

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

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

4. Never use recovery straps with your winch. Recovery straps are

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

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

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

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

77

WINCH GUIDE

Winch Maintenance and Service Safety

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

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

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

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

winch.

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

connections to prevent accidental activation of the winch.

4. For your safety, always replace POLARIS winch parts (including

the cable) with genuine POLARIS replacement parts available at
your authorized POLARIS dealer.

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

winches use a specially designed synthetic rope as the winch cable.

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

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

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

78

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

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

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

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located on the left front frame tube of the vehicle.

Electromagnetic Interference

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

directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic

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

79

MAINTENANCE

Periodic Maintenance Chart

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

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

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

Inspect, clean, lubricate, adjust and replace parts as necessary. When
inspection reveals the need for replacement parts, genuine POLARIS
parts are available from your POLARIS dealer . Equivalent parts may be
used for emissions-related service.

Record maintenance and service in the Maintenance Log beginning on
page 144.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Frequent short trip operation in cold weather (engine frequently does

not operate long enough to reach full operating temperature)

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. Your POLARIS dealer can assist.

80

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Ź Perform these operations more often for vehicles subjected to severe

use.

D Have an authorized POLARIS dealer or other qualified person

perform these services.

WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer or other qualified person perform these services.

81

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

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

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

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Steering - Pre-Ride - Make adjustments as need

ed. See Pre-Ride Checklist
on page 50.

Front suspension - Pre-Ride ­Rear suspension - Pre-Ride ­Tires - Pre-Ride ­Brake fluid level - Pre-Ride ­Brake pedal travel
Brake system - Pre-Ride ­Wheels/fasteners - Pre-Ride ­Frame fasteners - Pre-Ride ­Engine oil level - Pre-Ride ­Coolant - Daily - Check coolant level

Ź Power steering unit (if

equipped)

- Daily - Inspect daily; clean often

Headlight/taillight - Daily - Check operation
Suspension bushings - Daily - Lubricate daily or after

each use in mud or water
Air filter - Weekly - Inspect; replace as needed
Fuel System 25 H Monthly - Inspect; cycle key to

pressurize fuel pump;

check lines and fittings for

leaks and abrasion

Ź Engine oil change

(break-in)

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

filter change at one month

Ź Front gearcase

(demand drive) fluid

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

check

Ź Transmission (main

gearcase) oil

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

check

D Drive clutch bolt

re-torque

25 H 1 M 500 (800) See your dealer to have

bolt re-torqued to 96 ft-lbs

(130 Nm)

Ź

D

Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 25 H Monthly 250 (400) Check terminals; clean;

test

Ź Engine breather filter

(if equipped)

25 H Monthly 150 (250) Inspect; replace if

necessary

Ź Air filter 25 H - 500 (800) Replace filter

82

MAINTENANCE

Periodic Maintenance Chart

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

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

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

Ź General lubrication 50 H 3 M 500 (800) Lubricate a ll fittings, pivots,

cables, etc.

D Throttle pedal 50 H 6 M 500 (800) Inspect for free movement;

replace pedal as needed

Throttle body air
intake ducts/flange

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

sealing/air leaks

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

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

Cooling system 50 H 6 M 500 (800) Inspect coolant strength

seasonally; pressure test
system yearly

Ź Engine oil change 50 H 6 M 1000 (1600) Perform a break-in oil change

at one month

Ź Oil filter change 50 H 6 M 1000 (1600) Replace with oil change
Ź Oil lines, fasteners 50 H 6 M 1000 (1600) Inspect for leaks and loose

fittings

Ź Front gearcase

(demand drive)
fluid

100 H 12 M 1000 (1600) Change fluid

Ź Transmission

(main gearcase) oil

100 H 12 M 1000 (1600) Change fluid

D Fuel system 100 H 12 M 1000 (1600) Cycle key to pressurize fuel

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

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

torque to specification

83

MAINTENANCE

Periodic Maintenance Chart

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

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

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles

(Km)

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

surfaces

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

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

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

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

D 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

Ź Shock Seals 100 H - - Inspect shock seals

Ź

D

Shocks - 12 M 1500 (2400) See your dealer for oil

change/seal inspection.

D Front wheel

bearings

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

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

Ź Spark arrester 200 H 24 M 2000 (3200) Clean daily when driving in

mud and water; replace a
cracked or damaged arrester
before operating (see pages

106-107)
Valve lash 200 H - 2000 (3200) Check; adjust as needed
Suspension

bushings

250 H 24 M 2000 (3200) Inspect; replace if necessary

Ź Spark plugs 500 H 36 M 5000 (8000) Replace, torque to

specification

Ź Coolant - 60 M - Replace coolant

D Toe adjustment - Inspect periodically; adjust

when parts are replaced
Headlight aim - Adjust as needed

84

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 5W-50 4-Cycle Oil and

PS-4 Extreme Duty 10W-50
4-Cycle Oil

See page 86.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.

See page 110.

Transmission Oil
(Main Gearcase)

AGL Gearcase Lubricant &
Transmission Fluid

See page 90.

Front Gearcase Fluid
(Demand Drive)

Demand Drive Fluid See page 92.

Prop Shaft U-Joint Grease Grease middle and rear fittings.
Front Control Arm Pivot

Bushings

All Season Grease or grease
conforming to NLGI No. 2

Grease 3 fittings on each side of
the vehicle.

St abilizer Bar Bushings All Season Grease or grease

conforming to NLGI No. 2

Remove engine access panel
and grease 2 fittings (one on
each side of vehicle)

Middle Prop Shaft

Grease Fitting

Rear Prop Shaft

Grease Fitting

85

MAINTENANCE

Lubrication Recommendations

Stabilizer Bar Bushings

(one on each side of vehicle)

Front Control Arm

Pivot Bushings

(3 per side)

Front Suspension

86

MAINTENANCE

Engine Oil

Oil Recommendations

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated

engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury . Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.

Oil may need to be changed more frequently if POLARIS oil is not
used. Do not use automotive oil. Follow the manufacturer's
recommendations for ambient temperature operation. See page 132 for
the part numbers of POLARIS products.

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

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

Ambient Temperature Range Recommended Oil

-35

° F to +100° F

(-37

° C to +38° C)

PS-4 5W-50 4-Cycle Oil

0

° F to 120° F

(-18

° C to +49° C)

PS-4 Extreme Duty

10W-50 4-Cycle Oil

87

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 79. Always use the recommended
engine oil.

Oil Check

Always check the oil when the engine is cold. If the engine is hot when
the oil is checked, the level will appear to be overfull.

Access the oil check dipstick through the right rear wheel well. Access
the oil fill cap through the service access panel on the floor of the cargo
box.

1. Position the vehicle on a
level surface.

2. Place the transmission in

PARK.

3. Remove the dipstick. Wipe

it dry with a clean cloth.

4. Reinstall the dipstick

completely. Remove the
dipstick and check the oil
level.

5. Remove the oil fill cap to

add the recommended oil
as needed. Maintain the oil
level between the
minimum and maximum
marks on the dipstick. Do
not overfill.

6. Reinstall the fill cap.

Reinstall the dipstick.

Oil Check

Oil Fill

88

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 79. Always change the oil filter
whenever changing oil.

Access the oil check dipstick through the right rear wheel well. Access
the oil fill cap through the service access panel on the floor of the cargo
box.

The crankcase drain plug is located on the bottom of the crankcase.
Access the drain plug through the access hole under the crankcase.

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

2. Clean the area around the crankcase drain plug.

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

3. Place a drain pan under the

engine crankcase and remove
the drain plug. Allow the oil
to drain completely.

4. Using an oil filter wrench,

turn the filter counter-clock­wise to remove it.

5. Using a clean dry cloth, clean

the filter sealing surface on
the crankcase.

Oil Filter

89

MAINTENANCE

Engine Oil

Oil and Filter Change

6. 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.

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

8. Reinstall the crankcase drain plug. Torque to 12 ft. lbs. (16 Nm).

9. Remove the oil fill cap and add 2.5 quarts (2.4 l) of recommended
oil. Reinstall the fill cap.

10. Remove the dipstick. Wipe it dry with a clean cloth.

11. Reinstall the dipstick completely. Remove the dipstick and check
the oil level.

12. Remove the oil fill cap to add the recommended oil as needed.
Maintain the oil level between the minimum and maximum marks
on the dipstick. Do not overfill.

13. Reinstall the fill cap.

14. Reinstall the dipstick.

15. Dispose of used filter and oil properly.

90

MAINTENANCE

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 94 for recommended lubricants,
capacities and torque specifications.

Fluid Check

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

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Check the fluid level.

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

5. Reinstall the fill plug. Torque to specification.

Fill Plug

91

MAINTENANCE

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. Torque to specification.

6. Add the recommended fluid to 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.

Demand Drive

Drain Plug

Transmission

Drain Plug

92

MAINTENANCE

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 94 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

to the bottom thread of the
fill plug hole.

4. Reinstall the fill plug.

Torque to specification.

Fill Plug

93

MAINTENANCE

Demand Drive Unit (Front Gearcase)

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.

5. Reinstall the drain plug. Torque to specification.

6. Add the recommended fluid to the bottom thread of the fill plug
hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Demand Drive

Drain Plug

Transmission

Drain Plug

94

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See
page 132 for the part numbers of POLARIS products.

Spark Plugs

Spark Plug Gap/Torque

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

damage. Always use POLARIS-recommended spark plugs or their
equivalent. Refer to the specifications section beginning on page

130.

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 95.

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

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug

Torque

Transmission

(Main Gearcase)

AGL Gearcase

Lubricant &

Transmission

Fluid

44 oz.

(1300 ml)

10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

Demand Drive

Unit (Front
Gearcase)

Demand Drive

Fluid

8.5 oz.

(250 ml)

8-10 ft. lbs.

(11-14 Nm)

8-10 ft. lbs.

(11-14 Nm)

Electrode Gap Spark Plug Torque

0.7-0.8 mm 7 ft. lbs. (10 Nm)

95

MAINTENANCE

Spark Plu gs

Spark Plug Removal and Replacement

1. Remove the cargo box access

panel.

2. Clean the area around the spark
plugs before removing the
plugs.

3. Remove the spark plug caps.

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

5. Reverse the procedure for
spark plug installation. Torque
to specification. See page 94.

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. Fouling may be caused by excessive oil or by
frequent short trips, especially in cold weather.

Spark Plugs

96

MAINTENANCE

Fuse/Relay Center

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/relay center is
located under the driver’s seat.

Periodically inspect the fuse box for moisture. If moisture is present,
leave the cover off to allow the moisture to dry. Reinstall the cover
before operating.

Label Value Function

FAN 20A Circuit Breaker Fan
EFI 10A Fuse EFI Relay, Injectors, Coil, ECM,

Chassis Relay Coil, Fan Relay Coil,
Fuel Pump Relay Coil

KEY 10A Fuse Gauge, EFI Relay Coil, EPS Relay

Coil, Key Switch

TERM 10A Fuse Under Hood Terminal Block, Interior

LED
EPS 25A Fuse Power Steering
LIGHTS 10A Fuse Headlights, Taillights, Dash Lights
DRIVE 10A Fuse All Wheel Drive (AWD)
ACCESSORY 10A Fuse 12V Receptacle

Fuse

Box

97

MAINTENANCE

Cooling System

The engine coolant level is maintained by the recovery system. The
recovery system components are the overflow bottle, radiator vent
fitting, 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

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix.
This antifreeze is already premixed and ready to use. Do not dilute with
water. See page 132 for the part numbers of POLARIS products.

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every five (5) years
and fresh Antifreeze 50/50 Premix added. See page 98 for changing
procedure.

Any time the cooling system has been drained for maintenance or repair ,
replace the coolant with fresh Antifreeze 50/50 Premix.

Radiator and Cooling Fan

Check and clean the screen and radiator fins daily when operating in
mud and water. Interference with the radiator air flow can lead to
overheating and consequent engine damage.

Do not obstruct or deflect air flow through the radiator by installing
unauthorized accessories in front of the radiator or behind the cooling
fan.

Always inspect at the intervals outlined in the Periodic Maintenance
Chart beginning on page 79.

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.

98

MAINTENANCE

Cooling System

Radiator Coolant Level/Changing Coolant

This procedure is required only if the cooling system has been drained
for maintenance and/or repair. If the overflow bottle has run dry, the
level in the radiator should also be inspected.

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.

1. Remove the hood. See page

30.

2. Slowly remove the radiator
pressure cap.

3. View the coolant level
through the opening.

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

5. Before reinstalling the
pressure cap, bleed the
system of trapped air.
Remove the engine access
panel behind the seats and
use a flat-blade screwdriver
to turn the bleed screw
slightly, allowing the air to
escape. Slowly add
additional coolant to the
radiator until air no longer
escapes and only coolant
flows from the bleed hole,
then tighten the bleed screw.

6. Reinstall the pressure cap.

Tip: Use of a non-standard pressure

cap will not allow the recovery
system to function properly.
Your POLARIS dealer can
provide the correct replacement
part.

Bleed Screw

Pressure Cap

Overflow Bottle