Polaris Scrambler 1000 Owner's Manual

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2017

Scrambler

® XP 1000 Zugmachine

Sportsman

® XP 1000 Zugmachine

Sportsman

® 1000

® XP 1000

® 1000

® XP 1000

® Touring XP 1000

Owner's Manual

for Maintenance and Safety

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

2017 Owner’s Manual

Scrambler® 1000

Scrambler® XP 1000

Sportsman® 1000

Sportsman® XP 1000

Sportsman® XP 1000 Zugmachine

Sportsman® Touring XP 1000

POLARIS®, SCRAMBLER® and SPORTSMAN® are trademarks of POLARIS Industries Inc.

Copyright 2016 POLARIS Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

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

P/N 9927460

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 27

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Emission Control Systems . . . . . . . . . . . . . . . 95

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 143

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 147

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 148

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 160

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

INTRODUCTION

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

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

• Snowmobiles • 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

Always follow the instructions and recommendations in this manual. The manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory-certified Master Service Dealer® (MSD) technician. Please see your dealer for all of your service needs during (and after) the warranty period.

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

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.

INTRODUCTION

Polaris Sales Europe Sàrl Route de I’Etraz Business Center A5 1180 Rolle, Switzerland Telephone +41213-218-700

DECLARATION OF CONFORMITY

January 1, 2016 Polaris Sales Europe Sàrl declares that the vehicle(s)

listed below conform to the essential requirements applicable to all terrain vehicles.

APPLICABLE EUROPEAN DIRECTIVES: TEST / EVALUATION METHODS

2006/42/EC as amended

(Machinery Directive)

EN 15997

2004/108/EC as amended

(EMC Directive)

UNECE R10

97/24/EC Chapter 8

MODEL COMMERCIAL NAME SERIAL NUMBER

A_ _SX _ 95_ _

(All combinations)

Sportsman XP 1000

Zugmachine

TAPS_ _95_G_ _ _ _ _ _ _

(All combinations)

A_ _SX _ 95_ _

(All combinations)

Sportsman 1000

Sportsman XP 1000

Sportsman Touring XP 1000

TAPS_ _95_G_ _ _ _ _ _ _

(All combinations)

A_ _SV _ 95_ _

(All combinations)

Scrambler 1000

Scrambler XP 1000

TAPS_ _95_G_ _ _ _ _ _ _

(All combinations)

INTRODUCTION

Engine Serial Number

Key Number

VIN

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: ___________________________________________________

Frame VIN: _____________________________________________________________

Engine Serial Number: ____________________________________________________

Key Number: ___________________________________________________________

SAFETY

WARNING

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

Ride responsibly. Know all laws and regulations concerning the operation of this vehicle in your area.

Failure to follow the warnings in this manual can result in serious injury or death. This POLARIS vehicle is not a toy and can be hazardous to operate. A collision or rollover can occur quickly, even during routine maneuvers, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating this POLARIS vehicle.

Safety Training

Never operate this vehicle without proper instruction. Take a training course.

For more information about safety, contact an authorized POLARIS dealer or visit the POLARIS web site at www.polaris.com.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.

Never allow anyone under 12 years of age to ride as a passenger on a 2up vehicle.

SAFETY

Restrictions

Towing is approved OFF-ROAD ONLY unless your vehicle is approved for on-road operation. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

Equipment Modifications

The warranty on your POLARIS vehicle may be terminated if any equipment has been added, or if any modifications have been made, that increase speed or power.

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

SAFETY

WARNING

Rider Safety

Serious injury or death can result if you do not follow the instructions and procedures listed here and throughout this manual.

Read and understand all warnings, cautions and operating procedures in this manual and on the safety labels before operating the vehicle.

Never operate this vehicle without proper instruction. Take a training course. Beginners should receive training from a certified instructor.

Never permit others to operate the vehicle unless they have read and understand this manual and all product labels, and have completed a certified safety training course.

Never allow anyone under 16 years of age to operate this vehicle.

Never allow anyone under 12 years of age to ride as a passenger on a 2-up vehicle.

Never carry a passenger on a 1-up vehicle.

Never carry more than one passenger on a 2-up vehicle. Do not carry a passenger on a 2-up vehicle until you have at least two hours of driving experience with the vehicle. See page 68.

Rider Safety

Operator and passenger must always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

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

SAFETY

Operating this ATV on public streets could result in a collision with another vehicle.

Never operate an off-road vehicle on any public street, road or highway, including dirt and gravel roads (unless designated for off-highway use).

Zugmachine only: This vehicle is approved for on-road operation.

SAFETY

Rider Safety

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

Always wear an approved helmet that fits properly. Wear eye protection (goggles or face shield), gloves, boots, long sleeves and long pants.

Never operate at excessive speeds. Travel and turn at speeds appropriate for the terrain, visibility, operating conditions, your skills and a passenger’s skills.

Always use the size and type of tires specified for your vehicle. Maintain the proper tire pressure.

Rider Safety

Always inspect your vehicle before each use to verify that it's in safe operating condition. See page

64. Follow the inspection and maintenance procedures outlined in this manual.

Keep both hands on the handlebars. Keep both feet on the footrests. A passenger should always be seated behind the operator with both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

SAFETY

Always travel slowly when operating on unfamiliar terrain. Use extra caution.

Always follow the procedures outlined in this manual for turning. See page 67.

Never turn sharply at excessive speeds, which can lead to vehicle overturn.

If the vehicle has been involved in an accident, always have an authorized POLARIS dealer inspect the entire vehicle for possible damage, including (but not limited to) brake, throttle and steering systems.

SAFETY

Rider Safety

Never attempt jumps or other stunts.

Always follow the procedures outlined in this manual for driving on hills. See page 74.

Always move the 4X4 switch to 4WDC before ascending or descending a hill.

Operating on excessively steep hills could cause a rollover. Never operate on hills too steep for the ATV or for your abilities.

• Never operate a 1-up ATV on hills steeper than 25°.

• Never operate a 2-up ATV on hills steeper than 15°.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills. See page 77.

Always follow the procedures outlined in this manual for crossing the side of a hill. See page 76.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. See page 78.

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill. See page 75.

Always follow the procedures outlined in this manual for operating over obstacles. See page 72.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding. See page 70.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water. See page 71.

Always follow the procedures outlined in this manual for driving in reverse. See page 73.

SAFETY

Rider Safety

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

• Refuel with the engine stopped. Refuel outdoors or in a well-ventilated area.

• 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.

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

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

Never exceed the stated load capacity for your vehicle. Cargo must be properly distributed and securely attached. Reduce speed and follow the instructions in this manual for carrying cargo or towing. Allow a greater distance for braking.

Never operate the vehicle on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the vehicle, you and your cargo, together with any other vehicles in your party.

Operating on paved surfaces may affect the handling and control of the vehicle and could result in loss of control. Avoid sudden turns or swift movement of the handlebars.

Always unlock the steering before starting the engine. See page 36.

Hot components can cause serious burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.

For more information about safety, contact an authorized

POLARIS dealer or visit the POLARIS web site at

www.polaris.com.

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

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.

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

Off-road style gloves with knuckle pads are the best for comfort and protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.

SAFETY

General Alert

Hill Operation Alert

Override Alert

4X4 (AWD) Alert

7182094

SPEEDO REVERSE OVERRIDE

7181426

<16<

7181539

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.

Sportsman XP 1000 Zugmachine Labels

General Alert (7181539)

Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. NEVER carry a passenger. This vehicle is approved for onroad use.

Override Alert / 4X4 (AWD) Alert (7182094)

Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181426)

Never operate this vehicle on HILLS steeper than 25°.

SAFETY

7181427

55 kg 110 kg

7181582

kPa/bar

7183226

45 kPa/0.5 bar 45 kPa/0.5 bar

Rack Alert

Clutch Cover Alert

Tire Pressure Alert

Safety Labels and Locations

Sportsman XP 1000 Zugmachine Labels

Tire Pressure Alert (7183226)

FRONT 45 kPa/0.5 bar REAR 45 kPa/0.5 bar

Clutch Cover Alert (7181427)

Keep body parts away from belt.

Rack Alert (7181582)

DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch.Max. Rack Loads: Front 55 kg Rear 110 kg

Safety Labels and Locations

General Alert

7181537

<16<

7181543

Hill Operation Alert

Override Alert

Scrambler XP 1000 Zugmachine Labels

SAFETY

General Alert (7181537)

Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry a passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

Hill Operation Alert (7181426)

Never operate this vehicle on HILLS steeper than 25°.

SCRAMBLER Override Alert (7181544) / 4X4 (AWD) Alert (7181543)

Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

SAFETY

Rack Alert

Clutch Cover Alert

Tire Pressure Alert

35 kPakPa 35 kPa

< 131kg

7181589

11 kg 23 kg

7181583

7181427

Safety Labels and Locations

Scrambler XP 1000 Zugmachine Labels

SCRAMBLER Rack Alert (7181583)

DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 11 kg Rear 23 kg

Clutch Cover Alert (7181427)

Keep body parts away from belt.

SCRAMBLER Tire Pressure/Load Alert (7181589)

TIRE PRESSURE IN kPa: FRONT 35 REAR 35 MAXIMUM WEIGHT CAPACITY 131 kg

Safety Labels and Locations

7181426

General Alert

Hill Operation Alert

7181543

SPORTSMAN

Override Alert/4X4 (AWD) Alert

SCRAMBLER Override Alert

4X4 (AWD) Alert

SPEEDO REVERSE OVERRIDE

7181544

7181537

<16<

7182094

SPEEDO REVERSE OVERRIDE

Scrambler and Sportsman XP 1000 Labels

SAFETY

General Alert (7181537)

Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry a passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

SPORTSMAN Override Alert / 4X4 (AWD) Alert (7182094) SCRAMBLER Override Alert (7181544) / 4X4 (AWD) Alert (7181543)

Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181426)

Never operate this vehicle on HILLS steeper than 25°.

SAFETY

55 kg 110 kg

7181582

7181427

11 kg 23 kg

7181583

35 kPakPa 35 kPa

< 131kg

7181589

45 kPakPa 45 kPa

7181588

< 261kg

Rack Alert (Sportsman)

Hitch Capacity Alert

Clutch Cover Alert

Tire Pressure/Load Alert

(Sportsman)

Rack Alert (Scrambler)

Tire Pressure/Load Alert

(Scrambler)

680 kg

68 kg

7182175

Safety Labels and Locations

Scrambler and Sportsman XP 1000 Labels

SPORTSMAN Tire Pressure/Load Alert (7181588)

TIRE PRESSURE IN kPa: FRONT 45 REAR 45 MAXIMUM WEIGHT CAPACITY 261 kg

SCRAMBLER Tire Pressure/Load Alert (7181589)

TIRE PRESSURE IN kPa: FRONT 35 REAR 35 MAXIMUM WEIGHT CAPACITY 131 kg

SPORTSMAN Rack Alert (7181582)

DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 55 kg Rear 110 kg

SCRAMBLER Rack Alert (7181583)

DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 11 kg Rear 23 kg

Hitch Capacity Alert (7182175)

TRAILER MAX WEIGHT: 680 kg ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 68 kg

Clutch Cover Alert (7181427)

Keep body parts away from belt.

Safety Labels and Locations

15°

7181536

7181538

<16<

General Alert

Hill Operation Alert

Override Alert

4X4 (AWD) Alert

7182094

SPEEDO REVERSE OVERRIDE

Sportsman Touring XP 1000 Labels

SAFETY

General Alert (7181538)

Before you operate this vehicle, read the owner’s manual. Never allow anyone under 16 years of age to operate this vehicle. Wear approved helmet, goggles, and protective clothing. Never use alcohol or drugs before or while operating. Never carry more than one passenger on this vehicle. Never operate the vehicle on any public street, road or highway.

Override Alert / 4X4 (AWD) Alert (7182094)

Improper use of override button can lead to loss of control resulting in severe injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.

Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

Hill Operation Alert (7181536)

Never operate this vehicle on HILLS steeper than 15°.

SAFETY

7181427

45 kPakPa 45 kPa

7182138

< 261kg

Rack Alert

Hitch Capacity Alert

Clutch Cover Alert

Tire Pressure/Load Alert

55 kg 110 kg

7181582

680 kg

68 kg

7182175

Safety Labels and Locations

Sportsman Touring XP 1000 Labels

Tire Pressure/Load Alert (7182138)

TIRE PRESSURE IN kPa: FRONT 45 REAR 45 MAXIMUM WEIGHT CAPACITY 261 kg

Clutch Cover Alert (7181427)

Keep body parts away from belt.

Rack Alert (7181582)

DO NOT TOW FROM RACK OR BUMPER. Tow only from tow hooks or hitch. Max. Rack Loads: Front 55 kg Rear 110 kg

Hitch Capacity Alert (7182175)

TRAILER MAX WEIGHT: 680 kg ON LEVEL GROUND HITCH MAXIMUM VERTICAL WEIGHT: 68 kg

FEATURES AND CONTROLS

Left Handlebar

Controls

(see page 28)

Work Light

Switch

Fog Light

Switch

Main Key

Switch

4X4

Switch

STOP

PARKING

LIGHTS ON

LIGHTS ON START

Switches

Sportsman Zugmachine Switches

Work Light Switch

The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road).

Fog Light Switch

Use the fog light switch to turn the fog light on or off.

4X4 Switch

See page 33.

Main Key Switch

STOP: End all electrical power to the vehicle.

LIGHTS ON: Turn the headlights on. The engine stop switch must be in the RUN position.

PARKING LIGHTS ON: After starting the engine, release the key switch to this position. The parking lights and taillights are on in this position.

START: Start the engine. The headlights are not on in this position. See page 65 for starting procedures.

FEATURES AND CONTROLS

Override

Switch

Engine

Stop

Switch

Headlight and

Momentary High Beam

Switch

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

Switches

Sportsman Zugmachine Switches

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF

RUN

Headlight and Momentary High Beam Switch

The lights do not operate unless the main key switch is on and the engine stop switch is in the RUN position.

High Beam

Low Beam

Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released.

Turn Signal Switch

Push the toggle switch either left or right to activate the corresponding turn signal light. The indicator on the pod will also

flash. Return the toggle to the center position to end the signal.

Horn Switch

Press the horn switch to sound the horn.

Hazard Warning Switch

Push the hazard warning switch to cause all turn signal lights to

flash simultaneously. Use this feature to alert others of an emergency or other situation requiring caution.

Override Switch

See page 33.

FEATURES AND CONTROLS

Fog Light Switch

Main Key Switch

Switches

Scrambler Zugmachine Switches

Momentary High Beam Switch

Press this switch with your left forefinger to activate the headlight high beam. The lights will return to low beam when the switch is released.

Winch Switch

See page 84 for winch information.

Fog Light Switch

Use the fog light switch to turn the fog light on or off.

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes (except in reverse). See page 45. To gain additional power while operating in reverse, press the override switch before opening the throttle. This will cancel the reverse speed limit function.

The reverse override switch also acts as a MODE switch when held down for approximately one half second. See the instrument cluster information beginning on page 45.

Tip: The override switch will not function as a MODE switch if the transmission

is in reverse.

Activating the override switch while the throttle is open can cause loss of control. Do not activate the override switch while the throttle is open.

FEATURES AND CONTROLS

STOP

PARKING

LIGHTS ON

START

Override

Switch

Engine

Stop

Switch

Light

Switch

Horn

Switch

Hazard

Switch

Turn

Signal

Switch

Switches

Main Key Switch

STOP: End all electrical power to the vehicle.

LIGHTS ON: Turn the headlights on. The engine stop switch must be in the RUN position.

PARKING LIGHTS ON: After starting the engine, release the key switch to this position. The parking lights and taillights are on in this position.

START: Start the engine. The headlights are not on in this position. See page 65 for starting procedures.

Do not attach a large key fob or key ring to the main switch. It may contact the gas tank cap when turning, causing an interruption to the electrical system and an unexpected engine shut-down during operation. This could result in serious injury or death.

Engine Stop Switch

The engine will not start or run when the switch is in the OFF position.

OFF (STOP)

RUN

Light Switch (High/Low Beam)

Use the light switch to change the headlights from high beam to low beam.

High Beam

Low Beam

FEATURES AND CONTROLS

4X4

Switch

Switches

Work Light Switch (if equipped)

The work light switch controls a light located in the pod. Use the light when additional light is needed at the front of the vehicle, but turn the work light off when driving the vehicle (on-road).

Turn Signal Switch

Push the toggle switch either left or right to activate the

corresponding turn signal light. The indicator in the gauge will also flash. Return the toggle to the center position and push it inward to end the signal.

Hazard Warning Switch

Push the hazard warning switch to cause all turn signal lights to flash simultaneously. Use this feature to alert others of an

emergency or other situation requiring caution.

Horn Switch

Press the horn switch to sound the horn.

4X4 Switch

Use the 4X4 switch to engage 4WDC (if equipped), 4X4 or 2X4. The vehicle automatically engages 4X4 when operating in reverse if the 4X4 switch is set to either 4X4 position.

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key

Switch

4X4

Switch

Headlight Switch

Engine Stop

Switch

STOP

LIGHTS ON

START

OFF OFFRUN

Switches

Scrambler/Sportsman Switches

Headlight Switch (SPORTSMAN)

Use the headlight switch to change the lights between high beam and low beam.

Main Key Switch

STOP: End all electrical power to the vehicle.

LIGHTS ON: Turn the headlights on. The engine stop switch must be in the RUN position.

START: Start the engine. After releasing the key, the switch returns to the LIGHTS ON position. See page 65 for starting procedures.

Engine Stop Switch

Move the stop switch left or right to the OFF position to stop the engine. Move the switch to the RUN position before attempting to start the engine. Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Override Switch

See page 33.

4X4 Switch

See page 33.

FEATURES AND CONTROLS

Fuel Tank

Cap

Switches

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system. To gain additional wheel speed while backing, release the throttle and depress the override switch.

Pressing the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before pressing the override switch.

The reverse override switch also acts as a MODE button when held down for approximately one half second. The transmission cannot be in reverse when using the override switch as a MODE button.

4X4 Switch

Use the 4X4 switch to engage 4WDC, 4X4 or 2X4. See page 42. The vehicle automatically engages 4X4 when operating in reverse if the

switch is set to either 4X4 position.

Fuel Tank

Always refuel with the engine stopped, and outdoors or in a well ventilated area. Refuel on a level surface.

Remove the fuel tank cap and add fuel. 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.

The fuel tank is designed to allow for the normal expansion of fuel. Do not overfill. Do not fill the tank neck.

Extreme Use Battery

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

FEATURES AND CONTROLS

Mirrors (if equipped)

Use the mirrors to assist in traffic maneuvers. Always check and adjust the mirrors before driving.

Throttle Lever

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Check the lever for proper operation before starting the engine. Check occasionally during operation.

Do not start or operate the vehicle with sticking or improperly operating throttle controls. Contact your dealer for repair if throttle problems arise.

Press the throttle lever to increase engine speed and vehicle movement.

Release the lever to reduce engine speed and vehicle movement.

FEATURES AND CONTROLS

Foot

Brake

Brakes

Aggressively applying the brakes when backing down a hill may cause rear tipover. Aggressively applying the brakes while moving forward may cause the rear wheels to skid and result in loss of control.

Read this owner's manual and understand the operation of all brake systems on this vehicle. Always use caution whenever applying the brakes.

Foot Brake

The all-wheel foot brake is located on the right footrest. The foot brake operates both front and rear brakes. Press the brake pedal down with your foot to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the foot brake, reduce brake pressure.

Hand Brake Lever

The hand brake operates both front and rear brakes. Squeeze the brake lever toward the handlebar to apply the all-wheel brakes.

If the rear wheels begin to skid or slide while using the brake, reduce lever pressure.

Operating the vehicle with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the vehicle with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.

FEATURES AND CONTROLS

Brakes

Parking Brake

1. Place the transmission in

PARK .

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake

lock, squeeze and release the brake lever.

Operating the vehicle while the parking brake is engaged could result in an accident and serious injury or death. Always release the parking brake lock before operating.

Steering Lock (if equipped)

Lock the steering to prevent unauthorized use or theft of the vehicle.

1. Turn the handlebars to the full left position.

Tip: The handlebars may also be locked in the full right position.

2. Insert the steering lock key and turn it clockwise.

3. Remove the key.

Tip: Place the steering lock keys in a safe place. The lock must be replaced if

the keys are lost.

4. Reverse the procedure to unlock the steering.

The handlebars are locked in the fully turned position when the steering is locked. Always unlock the steering before starting the engine.

FEATURES AND CONTROLS

Gear

Selector

Electronic Power Steering (EPS)

Electronic power steering engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 45 for EPS Warning Indicator information.

Automatic Transmission Gear Selector

The transmission gear selector is located on the right side of the vehicle.

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

Stop the vehicle, release the throttle and move the shift lever to the desired gear. See your dealer if you experience any shifting problems.

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

moving could cause transmission damage.

Whenever the vehicle is left unattended, always place the transmission in PARK. The transmission is locked when it’s in PARK.

Belt Life

To extend belt life, use low forward gear when pulling a heavy load at less than 11 km/h for extended periods and when operating uphill at a slow speed.

FEATURES AND CONTROLS

Brake Fluid

Reservoir

Fuse Box/Relay

Recovery

Bottle Cap

Battery

Radiator

Cap

Recovery

Bottle

Cap

Radiator

Cap

Battery

Fuse Box/Relay

Foot Brake Fluid Reservoir

SPORTSMAN

SCRAMBLER

Latches

Front Compartment

Front Rack (SPORTSMAN XP 1000)

Release the front rack latches and remove the rack to gain access to the front compartment. To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches.

FEATURES AND CONTROLS

Cover Latches

Plunger Latches

Latches

Front Compartment

Front Storage Box (Touring)

Open the front storage box to access the under-compartment area.

1. Release the front box cover latches and lift the cover.

2. Release the plunger latches that

secure the box to the frame.

3. Close the cover and lift the

unlatched edge of the box to disengage the plungers. Pivot the box forward.

4. To remove the box completely,

disengage the plungers and slide the box rearward and upward.

5. Always secure the plunger latches

and the cover latches before operating the vehicle.

Front Rack/Compartment (SCRAMBLER)

Release the front rack latches and remove the rack to gain access to the front compartment.

To reinstall the rack, hold the rack as shown in the illustration. Position the front edge in the tabs, then push the rack downward and secure the latches.

FEATURES AND CONTROLS

Hitches

See the specification section beginning on page 148 for hitch weight capacities.

Do not tow a vehicle or a trailer with this vehicle unless all instructions have been followed. See pages 80-82.

Whenever the vehicle is towing, always stay clear of the area between the vehicle and the towed object.

Rear Hitch (Zugmachine)

Use the rear hitch for towing a trailer. See pages 80-82 for procedures.

Rear Hitch Specifications

Material S355J2+N Fasteners Metal pin with security cotter pin Weld Length and Positions 4 mm fillet, all around Maximum Vertical Load 75 kg applied on coupling point Maximum Towable Mass 750 kg Approval # E9-55R-01 6121

Rear Hitch Certification Label (Zugmachine)

The hitch certification label is located near the hitch on models equipped with a factory-installed rear hitch.

FEATURES AND CONTROLS

Cotter Pin

Hitch Pin

Step 4

Step 5

7-Way Trailer Connector

Hitches

Hitch Removal/Installation

1. To remove the hitch, remove the cotter pin and hitch pin. Remove the hitch, then reinstall the hitch pin and secure the cotter pin.

2. To install the hitch, remove the cotter pin from the hitch pin and

remove the hitch pin.

3. Install the hitch to the receiver.

4. Reinstall the hitch pin (from the left side of the hitch) through the

bore of both the receiver and the hitch.

5. Reinstall the cotter pin. Make sure the hitch assembly is secure at

that the cotter pin is properly engaged over the hitch pin.

7-Way Trailer Connector (Zugmachine)

The 7-way trailer connector installed on your vehicle meets the requirements of European standard ISO 1724.

This connector uses all 7 pins on newer model trailers. An older model trailer may not be compatible with this connector.

Improper electrical wiring changes can result in damage to both vehicle and trailer components. When in doubt about your trailer connection, please contact a qualified towbar specialist for assistance.

FEATURES AND CONTROLS

AWD

Switch

RPM

All Wheel Drive System

The All Wheel Drive system is controlled by the AWD momentary switch.

Engage AWD 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 or 4WDC AWD (if equipped) while the rear wheels

are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD or 4WDC AWD (if equipped) while the rear wheels have traction or are at rest.

AWD Mode

Move the momentary switch to the far right to engage AWD. AWD will engage when engine speed slows to below 3100 RPM. The gauge will display “AWD”.

There is no limit to the length of time the vehicle may remain in AWD. The vehicle automatically engages AWD when operating in reverse if the switch is set to the AWD position.

Once enabled, AWD remains enabled until the 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.

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.

2X4 Mode

Move the momentary switch to the far left to operate in two-wheel drive. AWD will disengage when engine speed slows to below 3100 RPM. The gauge will display “2X4”.

FEATURES AND CONTROLS

RPM

All Wheel Drive System

4WDC AWD Mode (if equipped)

Move the momentary switch to the right, past the AWD setting, to engage 4WDC (if equipped). When the switch is on 4WDC, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to 4WDC before ascending or descending a hill.

Four-Wheel Descent Control (4WDC) System

The 4WDC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to 4WDC before ascending or descending a hill.

Engaging Four-Wheel Descent Control

The 4WDC system will automatically engage when all four of the following conditions occur:

• The 4X4 switch must be in the 4WDC position

• The throttle must be closed (throttle lever released)

• The transmission must be in gear (high, low or reverse)

Disengaging Four-Wheel Descent Control

The 4WDC system will automatically disengage if at least one of the following conditions occur:

• The 4X4 switch is moved out of the 4WDC position

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

• The vehicle is on flat ground, or not actively descending a hill

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Indicator Lamps

Instrument Cluster

NOTICE: High water pressure may damage ATV components. Wash the ATV

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.

Digital/Analog Gauge

Speedometer

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

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Indicator Lamps

Lamp Indicates Condition

When standard mode is selected, speed displays in Vehicle Speed

miles per hour.

When metric mode is selected, speed displays in

kilometers per hour.

Over Temperature

EPS Warning This indicator illuminates when the key is turned to

Neutral This lamp illuminates when the transmission is in

High Beam This lamp illuminates when the headlamp switch is

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

This lamp flashes to indicate an overheated engine. If

the indicator stops flashing but remains illuminated,

the overheating condition remains, and the system

will automatically reduce engine power.

the ON position and goes off when the engine is

started. If the light remains on after starting the

engine, the EPS system is inoperative. See your

authorized POLARIS dealer for service.

neutral and the ignition key is in the ON position.

set to high beam.

Do not operate the ATV if this warning appears.

Serious engine damage could result. See your dealer.

FEATURES AND CONTROLS

Trip 1

RPM

Instrument Cluster

Digital/Analog Gauge

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, take the ATV to your POLARIS dealer for 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 48.

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

1. Gear Display - This area displays gear shifter position. H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

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

2. Fuel Gauge Display - 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. See your dealer.

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

engine hour meter, engine speed and programmable service hour interval.

4. Four-Wheel Descent Control Display - This icon displays when

4WDC is active. See page 45.

5. Clock Display - The clock displays time in a 12-hour or 24-hour

format. If the engine is turned off, press the MODE button. The time will display for 5-10 seconds. See page 49 for resetting instructions.

6. Service Reminder Display - A flashing wrench symbol alerts the

operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 49 for resetting instructions.

7. 4X4 Display - This icon displays when the 4X4 system is engaged

(switch is on either 4WDC or 4X4).

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

Rider Information Center

The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.

Display Units (Standard/Metric)

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

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

automatically exits and returns to the odometer display.

Standard Display Metric Display Distance Miles Kilometers Time 12-Hour Clock 24-Hour Clock

1. Turn the key to the OFF position.

2. Place the transmission in neutral.

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

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

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

6. Repeat the procedure to change remaining display settings.

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

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.

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

FEATURES AND CONTROLS

Instrument Cluster

Digital/Analog Gauge

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. Please see your POLARIS dealer 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.

FEATURES AND CONTROLS

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

Instrument Cluster

Digital/Analog Gauge

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 in the gauge 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. Please see your Polaris dealer for all major repairs.

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 numbers displayed in the gear position (if any), 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.See pages 58-61 for code definitions and failure descriptions. Please see your POLARIS dealer for all major repairs.

FEATURES AND CONTROLS

Instrument Cluster

Digital Gauge (if equipped)

The instrument cluster displays critical vehicle information to the user. Reference the following page for display functions and descriptions.

NOTE: Some features are not applicable to all models.The use of a high pres-

sure washer may damage the instrument cluster. Wash the vehicle by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will damage the instrument cluster lens. 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.

FEATURES AND CONTROLS

Instrument Cluster

Premium Gauge

1. Gear Display - This area displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

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

2. Display Area 2 - This area displays odometer, trip meter, trip meter

2, voltage, engine temperature, engine hour meter, programmable service hour interval, ground speed, or engine RPM.

3. Display Area 1 - This area displays engine RPM, ground speed, or

coolant temperature.

4. 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.

5. 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 60 for more information.

6. Clock - The clock displays time in a 12-hour or 24-hour format. See

page 56 for more information.

7. AWD Indicator - Segments of the indicator illuminate based on

drive mode engaged.

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

1 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 authorized POLARIS dealer can assist.

2EPS Warning

(if equipped)

3 Engine Hot This lamp illuminates to indicate an overheated

4 Neutral This lamp when the transmission is in neutral and

5 Helmet/Seat Belt This lamp flashes for several seconds when the key

6 High Beam This lamp illuminates when the headlamp switch is

7 Chassis Fault Not applicable.

This indicator illuminates when a fault has occurred in the EPS system. Your authorized POLARIS dealer can assist. EPS operation is possible with key on/engine off for up to 5 minutes.

engine. If the indicator flashes, a severe overheating condition exists.

the ignition key is on the ON position.

is turned to the ON position. The lamp is a reminder to wear helmet and seat belt before operating.

set to high beam.

8 Performance

Limited

Not applicable.

FEATURES AND CONTROLS

Instrument Cluster

Display Area 1

Pressing the MODE button will change the information displayed in Area 1.

Display Area 1 options:

•Speed

•RPM

• Engine Temperature

• Ambiant Temperature (optional)

FEATURES AND CONTROLS

Instrument Cluster

Display Area 2

Toggle the UP/DOWN buttons to change the information displayed in Area 2.

Display Area 2 options:

•Odometer

•Trip 1

•Trip 2

• Voltage

•Trip Timer

• Engine Tempurature

• Ambiant Temperature (optional)

•RPM

•Engine Hours

•Service Hours

•Speed

FEATURES AND CONTROLS

Instrument Cluster

Options Menu

Press and hold the MODE button to enter the Options Menu.

Options Menu Notes

Diagnostic Codes Only displays if fault codes are present or stored Units - Distance Select MPH or KPH Units - Temp

Clock Select between 12H or 24H, and set time Backlight Color Select between Blue or Red Backlight Level Set backlight brightness level Service Hours View/Set Service hours Exit Menu Exit

Select between°F and °C

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Open Load:

There is a break in the wires that lead to the item listed in

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load:

The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery:

The wire leading from the item listed in the chart to

the electronic control unit is shorted to a wire at battery voltage.

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor Voltage Too High 51 3

Voltage Too Low 51 4

Engine Temperature Sensor Voltage Too High 110 3

Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0

Intake Air Temperature Sensor Voltage Too High 105 3

Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4 Signal Out of Range 102 2

Crankshaft Position Sensor Circuit Fault 636 8

Plausibility Fault 636 2

Vehicle Speed Signal Speed Too High 84 8

Plausibility Fault 84 2

Gear Sensor Signal Voltage Too Low 523 4

Voltage too high 523 3 Signal fault 523 2

Injector 1 (MAG) (SDI Part Load) Driver Circuit Open/Grounded 651 5

Driver Circuit Short to B+ 651 3 Driver Circuit Grounded 651 4

Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded 652 5

Driver Circuit Short to B+ 652 3 Driver Circuit Grounded 652 4

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Ignition Coil Primary Driver 1 (MAG) Driver Circuit Short to B+ 1268 3 Ignition Coil Primary Driver 2 (PTO) Driver Circuit Short to B+ 1269 3 Fuel Pump Driver Circuit Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3 Driver Circuit Grounded 1347 4

Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Driver Circuit Short to B+ 1071 3 Driver Circuit Grounded 1071 4

Idle Air Control Driver Circuit Open/Grounded 634 5

Driver Circuit Short to B+ 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7

Starter Enable Circuit Driver Circuit Open/Grounded 1321 5

Driver Circuit Short to B+ 1321 3 Driver Circuit Grounded 1321 4

Chassis Relay Driver Circuit Open/Grounded 520208 5

Driver Circuit Short to B+ 520208 3 Driver Circuit Grounded 520208 4

All Wheel Drive Control Driver Circuit Open/Grounded 520207 5

Driver Circuit Short to B+ 520207 3 Driver Circuit Grounded 520207 4

System Power Voltage Too High 168 3

Voltage Too low 168 4

Throttle Safety Signal Voltage Too High 520194 3

Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7

Active Descent Control System Driver Circuit Open/Grounded 520203 5

Driver Circuit Short to B+ 520203 3 Driver Circuit Grounded 520203 4

Idle Speed Speed Too High 520211 3

Speed Too Low 520211 4

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

EPS Models Only

Vehicle Speed Sensor Data Valid But Above Normal

Operational Range - Most Severe Level

Data Erratic, Intermittent Or Incorrect

Abnormal Rate Of Change 84 10 Received Network Data In Error 84 19

System Power Data Valid But Above Normal

Operational Range - Most Severe Level

Voltage Above Normal, Or Shorted To High Source

Voltage Below Normal, Or Shorted To Low Source

Engine Speed Data Valid But Above Normal

Operational Range - Most Severe Level

Data Erratic, Intermittent Or Incorrect

Received Network Data In Error 190 19

ECU Memory Bad Intelligent Device Or

Component

Out Of Calibration 628 13 Calibration Out Of Calibration 630 13 Steering Over Current Shut Down Current Above Normal Or

Grounded Circuit Steering Excessive Current Error Current Above Normal Or

Grounded Circuit Steering Torque Partial Failure Condition Exists 520223 31

Steering Torque Full Failure Condition Exists 520224 31

84 0

84 2

168 0

168 3

168 4

190 0

190 2

628 12

520221 6

520222 6

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

EPS Models Only

EPAS Inverter Temperature Data Valid But Above Normal

Operational Range - Most Severe Level

Data Valid But Above Normal Operating Range - Moderately Severe Level

EPAS Communications Receive Data Error

Position Encoder Error Root Cause Not Known 520228 11

EPAS Software Error Bad Intelligent Device Or

EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Voltage Error Voltage Above Normal, Or

Data Erratic, Intermittent Or Incorrect

Condition Exists 520226 31

Bad Intelligent Device Or Component

Condition Exists 520228 31

Component Condition Exists 520229 31

Shorted To High Source Voltage Below Normal, Or

Shorted To Low Source

520225 0

520225 16

520226 2

520228 12

520229 12

524086 3

524086 4

OPERATION

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

Break-In Period

The break-in period for your new POLARIS vehicle is the first 20 hours of operation. No single action on your part is as important as following the procedures for a proper break-in. Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components.

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.

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 33. Always exercise extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 101. Add oil if

necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to

familiarize yourself with vehicle operation and handling.

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

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

on the daily pre-ride inspection checklist. See page 64.

6. Pull only light loads.

7. Change both the oil and the filter at 25 hours.

8. Check the fluid level of the transmission after the first 25 hours of

operation and every 100 hours thereafter.

PVT Break-in (Clutches/Belt)

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

If a belt fails, always clean away all debris when replacing the belt.

OPERATION

Pre-Ride Checklist

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

Passenger seat latch (if equipped)

Hand brake/lever travel Ensure proper operation 113

Foot brake Ensure proper operation 113

Brake fluid Ensure proper levels 111

Front suspension Inspect, lubricate if necessary 100

Rear suspension Inspect, lubricate if necessary 100

Steering Ensure free operation -

Tires Inspect condition and pressure 117

Wheels/fasteners Inspect, ensure fastener tightness 117

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 33

Coolant level Ensure proper level 109

Coolant hoses Inspect for leaks -

Throttle Ensure proper operation 34

Ensure latch is secure 115

118

101

110

Indicator lights/switches Ensure proper operation 27

Engine stop switch Ensure proper operation 28, 32

Air filter, pre-filter Inspect, clean 119

Headlights Check operation 28, 32

Brake light/tail lamp Check operation 123

Riding gear Wear approved helmet, goggles, and

protective clothing

Mirrors (if equipped) Adjust for best side/rear vision -

Winch (if equipped) Inspect cable and switch. 83-94

OPERATION

Starting the Engine

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

Tip: The starter interlock will prevent the engine from starting if the transmission

is in gear and the brake is not engaged.

3. Sit on the vehicle. Move the engine stop switch to RUN.

4. Do not press the throttle while starting the engine.

5. Turn the ignition key to the START position to engage the starter.

Activate the starter for a maximum of five seconds, releasing the key when the engine starts.

6. If the engine does not start, return the key to the OFF position and

wait five seconds before attempting to start again. Activate the starter for another five seconds if necessary. Repeat this procedure until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Cold Weather Operation

If the vehicle is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase. Water in the bottom of the crankcase can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

See your POLARIS dealer for engine heater kits, which provide quicker warm-ups and easier starting in colder weather.

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 17.

2. Perform the pre-ride inspection. See page 64.

3. Place the transmission in PARK.

4. Mount the vehicle from the left side.

5. Sit upright with both feet on the footrests. Keep both hands on the handlebars.

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

7. Apply the brakes.

8. Shift the transmission into gear.

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

10. Release the brakes.

11. Slowly depress the throttle with your right thumb and begin driving.

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

Turning the Vehicle

1. Before turning, activate a turn signal to alert others of your intentions. Activate the left signal before a left turn. Activate the right signal before a right turn.

2. Steer in the direction of the

turn, leaning your upper body to the inside of the turn while supporting your weight on the outer footrest. Use the same leaning technique for turning in reverse.

3. Practice making turns at

slow speeds before attempting to turn at faster speeds.

OPERATION

4. Never turn quickly when carrying a passenger or cargo.

Always follow the procedures outlined in this manual for turning. Never turn sharply at excessive speeds, which can lead to vehicle overturn.

OPERATION

Driving with a Passenger

1. Never carry a passenger on a 1-up vehicle. Never carry more than one passenger on a 2-up vehicle.

2. Do not carry a passenger on a 2-up vehicle until you have at least

two hours of driving experience with the vehicle.

3. Never allow anyone under 12 years of age to ride as a passenger on

a 2-up vehicle. Make sure any passenger is tall enough to comfortably and safely reach the grab handles and footrests. Allow a passenger to ride only in the approved passenger seat.

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

including an approved helmet with a rigid chin guard. See page 17.

5. Perform the pre-ride

inspection. See page 64.

6. Always make sure the

passenger seat is installed and securely latched before operating with a passenger.

7. Lock the parking brake.

8. Mount the vehicle from the

left side. After the operator is seated, the passenger should mount the vehicle from the left side. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts.

9. Do not carry more than one passenger.

10. Slow down. Control may be more difficult with a passenger on

board. Allow more time and distance for braking.

OPERATION

Driving with a Passenger

11. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.

12. Do not cross a hillside with a passenger on board. See page 76.

13. A passenger should always be seated behind the operator with both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

14. Make sure the passenger understands the importance of “active riding.” When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.

OPERATION

Sideways

Skid

Turn in direction

of skid

Driving on Slippery Surfaces

Whenever driving on slippery or loose surfaces such as wet trails, gravel, snow or ice, follow these precautions:

1. Slow down when entering slippery areas.

2. Engage 4X4 before wheels begin to lose traction.

NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while

the wheels are spinning. Allow the rear wheels to stop spinning before engaging 4X4, or engage 4X4 before wheels begin to lose traction.

3. Be alert. Watch the trail. Avoid quick, sharp turns

4. Never apply the brakes during a skid. Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward.

Always follow the procedures outlined in this manual for operating on slippery or loose surfaces. Use extra caution. Always avoid skidding or sliding.

OPERATION

Maximum

Depth

Driving Through Water

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

2. Choose a crossing where

both banks have gradual inclines.

3. Drive slowly. Avoid rocks

and obstacles.

4. Avoid operating in water

deeper than the bottom of the footrests. If it’s unavoidable, travel slowly, balance your weight carefully and avoid sudden movements. Maintain a slow and steady forward motion. Do not make sudden turns, stops or throttle changes.

NOTICE: If the vehicle stops while fully submerged, major engine damage can

result if the machine is not thoroughly inspected. Take the vehicle to your dealer before starting the engine.

5. Wet brakes may have reduced stopping ability. Dry the brake pads

by driving slowly and applying the brakes lightly several times until braking action is normal.

6. If your vehicle becomes fully immersed, and it’s impossible to take

it to a dealer before starting it, follow the steps described on page

127. Have the vehicle serviced by your dealer promptly.

Always follow the procedures outlined in this manual for driving through water. Never drive through deep or fast-flowing water.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Be alert. Watch the terrain. Use extra caution.

3. Never attempt to operate over large obstacles, such as rocks or fallen trees.

4. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle rollover.

Always follow the procedures outlined in this manual for operating over obstacles.

Driving in Reverse

OPERATION

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view.

2. Avoid backing downhill.

3. Drive slowly. Apply the brakes lightly for stopping.

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional wheel speed is

required for vehicle movement. Use with caution.

NOTICE: Excessive throttle operation while in the speed limit mode may cause

fuel to build in the exhaust, resulting in engine popping and/or engine damage.

Always follow the procedures outlined in this manual for driving in reverse.

OPERATION

1-Up Models

25° Maximum

2-Up Models

15° Maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to 4WDC before ascending or descending a hill. See page 42.

2. Drive straight uphill.

3. Avoid steep hills. Maximum incline is:

• 15° (2-Up Models)

• 25° (1-Up Models)

4. Avoid hills with slippery or loose surfaces.

5. Keep both feet on the footrests.

6. Shift body weight uphill. A passenger should also shift body weight

uphill.

7. Proceed at a steady rate of speed to avoid stalling.

8. Be alert. Be prepared to take emergency action. This may include

dismounting quickly.

9. Never open the throttle suddenly or make sudden gear changes.

10. Never go over the top of a hill at high speed.

OPERATION

Driving Uphill

If all forward speed is lost:

1. Keep your weight uphill. A passenger should also lean uphill.

2. If the vehicle begins rolling downhill, never apply engine power. Never apply the brakes aggressively while rolling backwards.

3. Apply the brakes gradually. When fully stopped, lock the hydraulic parking brake.

4. Dismount on the uphill side, or on the left side if the vehicle is pointed straight uphill. Have a passenger dismount first, then the operator may dismount.

5. Use the K-turn to turn around. See page 78.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

OPERATION

Driving on a Sidehill (Sidehilling)

Avoid crossing the side of a hill (sidehilling) if possible. If sidehilling is necessary, follow these precautions:

1. Slow down.

2. Shift body weight uphill.

3. Keep your feet on the footrests.

4. Avoid hills with slippery or loose surfaces.

5. Avoid crossing the sides of steep hills.

6. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.

7. If the vehicle begins to slide or tip, quickly turn the front wheel downhill, if possible, or dismount on the uphill side immediately!

Always follow the procedures outlined in this manual for crossing the side of a hill.

Never attempt to turn the vehicle around on any hill until you've mastered (on level ground) the turning technique outlined in this manual.

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to 4WDC before ascending or descending a hill. See page

42.

2. Avoid steep hills. Maximum

incline is:

• 15° (2-Up Models)

• 25° (1-Up Models)

3. Avoid hills with slippery or

loose surfaces.

4. Never drive downhill at high speed. Slow down.

5. Drive straight downhill. Avoid driving downhill at an angle, which

can cause the vehicle to pitch sharply to one side.

6. Shift body weight uphill. A passenger should also shift body weight

uphill.

7. Apply the brakes slightly to aid in slowing.

Always follow the procedures outlined in this manual for driving downhill and for braking on hills.

OPERATION

2.4 m

Turning Around on a Hill (K-Turn)

If the vehicle stalls while climbing a hill, never back it down the hill! Use the K-turn to turn around.

1. Stop the vehicle. Keep your weight uphill.

2. Always move the 4X4 switch to 4WDC before ascending or descending a hill. See page 42.

3. Lock the hydraulic parking brake.

4. Leave the transmission in forward gear. Turn the engine off.

5. If a passenger is on board, ask the passenger to dismount first, then the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A

passenger should not remount until the vehicle returns to firm, level ground.

6. Stay uphill of the vehicle and turn the handlebars full left.

7. Squeeze the brake lever to release the parking brake.

8. Slowly release the brake lever and allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill. A passenger should not remount until the vehicle returns to firm, level ground.

11. Apply the foot brake.

12. With the transmission still in forward, start the engine.

13. Squeeze and release the brake lever to release the parking brake.

14. Release the foot brake and drive slowly downhill. Control speed with either the hand or foot brake until the vehicle is on level ground.

Always follow the procedures outlined in this manual for driving on hills. See page 74. Never operate on hills too steep for the vehicle or for your abilities. Practice on smaller hills before attempting larger hills. Avoid climbing hills steeper than 25°.

Always follow the procedures outlined in this manual for braking if you stall or roll backwards while climbing a hill. Never back down a hill.

OPERATION

Hauling Cargo

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

• Read and understand the load distribution warnings listed on the vehicle warning labels.

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

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO OR TOWING. Use extreme caution when applying brakes. Avoid situations that require backing downhill.

• WEIGHT DISTRIBUTION on models with front and rear racks should be 1/3 on the front rack and 2/3 on the rear rack. Carrying loads on only one rack increases the possibility of vehicle overturn.

• CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.

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

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

• Towing is approved OFF-ROAD ONLY unless your vehicle is approved for onroad operation.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when towing loads in rough terrain, while cornering, or while ascending or descending hills.

OPERATION

1/3

2/3

Hauling Cargo

1. Never exceed the weight capacities specified for your vehicle on warning labels and in the specifications section of this manual.

2. On models with front and rear

racks, cargo weight should be evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.

3. When operating over rough or

hilly terrain, reduce speed and cargo weight to maintain stable driving conditions.

4. All Models except SCRAMBLER:

NEVER exceed 80 km/h when rear cargo loads are above 34 kg and/or front cargo loads are above 17 kg.

5. Touring Models only:

NEVER exceed 80 km/h while carrying a passenger. NEVER exceed 16 km/h when rear cargo loads are above 91 kg and/or front cargo loads are above 45 kg.

6. Use low forward gear when hauling or towing heavy cargo to

extend belt life.

OPERATION

Hauling Cargo

Towing Loads

Towing is approved OFF-ROAD ONLY unless your vehicle is approved for on-road operation. See your POLARIS dealer about configuring the vehicle to be certified to tow a trailer on-road.

• Do not tow any trailer on a grade steeper than 15°.

• Always attach a towed load to the hitch point. Remove the hitch from the vehicle when not towing a trailer.

• If towing a load, reduce rear rack cargo weight by the amount of tongue weight. The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

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

• For Zugmachine, unbraked trailer towing capacity is 180 kg based on EU Directive 76/432/EC. Braked trailer towing capacity is 805 kg.

• For all other models, unbraked trailer towing capacity is 750 kg based on EU Directive 76/432/EC.

NOTICE: Using an improper hitch or exceeding the maximum tongue weight

capacity can result in serious damage to the vehicle and will void your vehicle warranty. Never install a hitch longer than 10 cm. Never install automotive accessories on your POLARIS vehicle. Always install POLARIS-approved (or equivalent) accessories designed for use on this vehicle.

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in

PA R K.

3. Always block the rear

wheels on the downhill side.

WINCH GUIDE

WARNING

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 92.

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

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

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

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

WINCH GUIDE

Winch Safety Precautions

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 90 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.

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.

WINCH GUIDE

Winch Safety Precautions

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

21. Never immerse or submerse your winch in water. Take your winch to your dealer for service 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.

WINCH GUIDE

WARNING

Hook Strap

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.

WINCH GUIDE

NO YES

YES

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 page 92.

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.

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.

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 92. 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.

WINCH GUIDE

Winch Operation

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

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

15. After winching is complete, especially if winching at an angle, it may be necessary to 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.

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.

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.

WINCH GUIDE

Shock Loading

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.

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.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

Do not modify the engine, intake or exhaust components, as doing so may affect compliance with governmental noise level requirements.

Spark Arrester

Your POLARIS vehicle has a spark arrester that was designed for onroad and off-road operation. It is required that this spark arrester remain installed and functional when the vehicle is operated.

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 right front frame of the vehicle.

Electromagnetic Interference

This vehicle complies with the EMC requirements of European directive 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.

European Vibration and Noise

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

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

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

many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

MAINTENANCE

Periodic Maintenance Chart

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

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

Record maintenance and service in the Maintenance Log beginning on page 160.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation

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

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

Symbol Description

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

D Have an authorized POLARIS dealer perform these services.

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

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

Steering -

Front suspension - -

Rear suspension - -

Tires - -

Brake fluid level - -

Brake lever travel - -

Brake system - -

Wheels/fasteners - -

Frame fasteners - -

Engine oil level - -

Winch - - See pages 83-94.

► Air filter, pre-filter - Daily - Inspect; clean often; replace

Coolant - Daily - Check level

Pre-Ride

See Pre-Ride Checklist on page 64.

as needed. See page 119.

Remarks

► Power steering unit

(if equipped)

Headlamp/taillight - Daily - Check operation

► Air filter, main

element

- Daily - Inspect daily; clean often

- Weekly - Inspect; replace as needed. See page 119.

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

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

Battery 20 H Monthly 200 (320) Check terminals; clean; test

Fuel system 20 H Monthly - Inspect; cycle key to

pressurize fuel pump; check lines and fittings for leaks and abrasion

► Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change

(see page 62)

► Demand drive fluid

(extreme use)

► Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check

► Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check

► Transmission oil 25 H 1 M 250 (400) Break-in oil level check

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

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

25 H 1 M 250 (400) Change fluid every 25 hours

if 4WDC is subjected to extreme use. See page 105.

cables, etc.

Remarks

D Steering 50 H 6 M 500 (800) Lubricate

► Front suspension 50 H 6 M 500 (800) Lubricate

► Rear suspension 50 H 6 M 500 (800) Lubricate

D Throttle Cable/

Throttle Release Switch

Throttle Body Intake Duct

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

Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength

► Radiator 50 H 6 M 1000 (1600) Inspect; clean external

► Cooling hoses 50 H 6 M 1000 (1600) Inspect for leaks

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

D Have an authorized POLARIS dealer perform these services.

50 H 6 M 500 (800) Inspect; adjust; lubricate;

replace if necessary

50 H 6 M 500 (800) Inspect duct for proper

sealing/air leaks

seasonally; pressure test system yearly

surfaces

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

(Km)

► Oil lines and

fasteners

► Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter

► Demand drive fluid

(normal use)

► Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid

► Transmission oil 100 H 12 M 1000 (1600) Change fluid

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

► Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

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

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

100 H 6 M 1000 (1600) Inspect for leaks and loose

fittings

100 H 12 M 1000 (1600) Change fluid

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

100 H 12 M 1000 (1600) Inspect

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

Remarks

D Clutches (drive

and driven)

D Front wheel

bearings

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

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

► Coolant - 60 M - Replace coolant

D Valve clearance 1000 H - 10000

D Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

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

parts

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

Inspect; adjust

(16000)

when parts are replaced

Polaris Scrambler 1000 Owner's Manual

Specifications and Main Features

Frequently Asked Questions

User Manual