Polaris Sporstman X2 800 EFI, Sportsman 500 X2, Sportsman 9920632, Sportsman 800 X2 User Manual

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WARNING

The engine exhaust from this

product contains chemicals known

to cause cancer, birth defects or

other reproductive harm.

A card containing important ATV safety information should be attached to the owner's manual on the next page. If you cannot locate this card, or if it has been removed, please call 1-800-3423764 for assistance.

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

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

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

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

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

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

Copyright 2006 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2007 Sportsman 500 X2/Sportsman 800 X2 Owner’s Manual P/N 9920632

TABLE OF CONTENTS

Know Your Vehicle . . . . . . . . . . . . . . . . . . . . . . . 5

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Features and Controls . . . . . . . . . . . . . . . . . . . 38

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Emission Control Systems . . . . . . . . . . . . . . . 84

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 139

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 143

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 144

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 154

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

KNOW YOUR VEHICLE

####

VIN

Engine Serial Number

Key Number

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.

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

Discretionary Warning

Age 16 Warning

Safety Decals and Locations

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

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

Discretionary Warning

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees 15°. To prevent flip-over on hilly terrain, when going up or down, use throttle and brakes gradually.

• Never operate this vehicle in TURF mode on irregular terrain, including hills and obstacles.

• REVERSE operation can be dangerous even at low speeds. Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of control, never activate override button with open throttle.

• When this ATV is not in operation, or unattended, place shift in the park position.

Age 16 Warning

WARNING Operating this ATV if you are under the age of 16 increases your chance of

severe injury or death. NEVER operate this ATV if you are under age 16.

SAFETY

General

Warning

Safety Decals and Locations

General Warning

WARNING Improper ATV use can result in SEVERE

INJURY or DEATH

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

NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN ONE

PASSENGER NEVER USE WITH DRUGS OR

ALCOHOL NEVER operate:

• without proper training or instruction

• at speeds too fast for your skills, your passenger’s skills, or the conditions

• on public roads - a collision can occur with another vehicle

• with more than one passenger - passengers affect balance and steering and increase risk of losing control

• with a passenger under the age of 12

THE OPERATOR MUST ALWAYS:

• use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns

• avoid paved surfaces - pavement may seriously affect handling and control

• reduce speed and use extra caution at all times when carrying a passenger have passenger dismount when conditions require

• make sure passenger reads and understands this label and passenger safety label

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

REPLACEMENT.

SAFETY

Passenger Safety

Warning

Safety Decals and Locations

Passenger Safety Warning

WARNING PASSENGER SAFETY to reduce the risk

of SEVERE INJURY or DEATH

NEVER CARRY A PASSENGER UNDER AGE 12

NEVER CARRY MORE THAN ONE PASSENGER

NEVER RIDE AFTER USING DRUGS OR ALCOHOL

NEVER carry a passenger too small to firmly plant feet on footrests and securely grasp hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective gear

• securely grasp hand holds and plant feet firmly on footrests

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

Safety Decals and Locations

Tire Pressure/Load

Warning

Tire Pressure/Load Warning

WARNING IMPROPER TIRE PRESSURE OR

OVERLOADING can cause loss of control resulting in SEVERE INJURY

OR DEATH.

TIRE PRESSURE IN PSI (KPa): FRONT 5 (34.5) REAR 5 (34.5)

MAXIMUM WEIGHT CAPACITY (Gross Vehicle Weight) INCLUDING MACHINE, OPERATOR, PASSENGER AND CARGO IS 1500 LBS. (680 kg).

Reduce speed and allow greater distance for braking when carrying cargo. Overloading or carrying tall, off-center, or unsecured loads will increase your risk of losing control. Loads should be centered, carried as low as possible in box, and firmly secured to the rack. For stability on rough or hilly terrain, reduce speed and cargo. Do not block headlight. Be careful if load extends over the side of the rack or box.

Read Owner's Manual for more detailed loading information.

SAFETY

Clutch Cover

Warning

Rack

Warning

Box

Warning

Safety Decals and Locations

Rack Warning, Front

WARNING DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may

result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 90 lbs. (41 kg)

Clutch Cover Warning

WARNING NO STEP

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

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

SAFETY

Safety Decals and Locations

Reverse Override Warning

WARNING Pushing reverse override button may cause sudden increases in power and

traction if too much throttle is applied. Loss of control or forward flipover may result, especially in AWD. See Owner's Manual.

Box Warning

WARNING Remove flammable material

containers from box before filling.

WARNING Passengers can be thrown off. This can cause serious

injury or death. Never carry passengers in cargo box. Maximum Box Load - 400 lbs. (181 kg)

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.

Helmet

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

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

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

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

Rider Safety

WARNING

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

A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

Read and understand your owner's manual and all warnings before operating a Polaris ATV.

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 this 2-up ATV.

SAFETY

Rider Safety

Safety Training

ATV safety training is a top priority for Polaris. When you purchased your new ATV, your dealer instructed you on the authorized ATV

RiderCoursesm available to you and your eligible family members. This

training is included in the purchase price of your ATV. Polaris strongly encourages you and your eligible family members who will be riding the ATV to take the ATV RiderCourse printed materials that explain safe operating procedures. You should review this information on a regular basis.

If you purchased a used Polaris ATV, you can take the ATV

RiderCourse

by calling A TV Enrollment Express at (800) 887-2887 or by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

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

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

. You were also provided with

SAFETY

Rider Safety

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

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

WARNING

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

CAUTION

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

CAUTION

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

NOTE

A note will alert you to important information or instructions.

SAFETY

Rider Safety

WARNING

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

• Read this manual and all labels carefully, and follow the operating

procedures described.

• Never operate an ATV without proper instruction. Take a training

course. Purchasers of a new Polaris ATV and their eligible family members are entitled to take the ATV RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org for information on enrollment in the ATV RiderCoursesm.

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

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

this 2-up ATV. Make sure any passenger is tall enough to comfortably and safely reach the handgrips and footrests.

• Never secure a passenger to the vehicle or to the operator with a belt,

rope or similar device.

• Never carry more than one passenger on this 2-up ATV.

• Always make sure the passenger seat lock-out is functioning properly

before carrying a passenger.

• Never permit a guest to operate the A TV unless the guest has read this

manual and all product labels and has completed a certified safety training course.

• Always keep both hands on the handlebars and both feet on the foot-

rests of the ATV during operation. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

• Always avoid operating an ATV on paved surfaces, including side-

walks, driveways, parking lots, and streets.

• Never operate an ATV on a public street, road or highway , including a

dirt or gravel road.

. Contact ATV

SAFETY

Rider Safety

• Never operate an ATV without wearing an approved helmet that fits properly . Always wear eye protection (goggles or face shield), gloves, boots, a long-sleeved shirt or jacket, and long pants. A passenger's helmet should have a rigid chin guard.

• Never consume alcohol or drugs before or while operating an AT V.

• Never operate at excessive speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.

• Never attempt jumps or other stunts.

• Always inspect your ATV before each use to make sure it's in safe operating condition. Always follow the inspection and maintenance procedures and schedules outlined in your owner's manual.

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

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

• Always follow proper turning procedures as described in this manual. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

• Always have the ATV inspected by an authorized Polaris dealer if it's been involved in an accident.

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

• Never operate this ATV in TURF mode while operating on a hill or other irregular terrain. See page 47.

• Always follow proper procedures for climbing hills. Check the terrain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift your weight uphill. Never open the throttle suddenly or make sudden gear changes. Never go over the top of a hill at high speed. Switch the AWD switch out of TURF mode and into AWD mode when ascending a hill.

SAFETY

Rider Safety

• Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift your weight uphill. Never go down a hill at high speed. Avoid going down a hill at an angle, which would cause the vehicle to lean sharply to one side. Drive straight downhill.

• Always follow proper procedures for crossing the side of a hill. Do

not cross a hillside with a passenger on board. Avoid hills with excessively slippery or loose surfaces. Shift your weight uphill. Never attempt to turn the ATV around on any hill until you've mastered (on level ground) the turning technique outlined in this manual. Avoid crossing the side of a steep hill when possible.

• Always use proper procedures if you stall or roll backwards while

climbing a hill. To avoid stalling, maintain a steady speed when climbing a hill. If you stall or roll backwards, follow the special procedure for braking described in this manual. Always dismount on the uphill side, or to either side if the ATV is pointed straight uphill. Turn the ATV around and remount following the procedure described in this manual.

• Always check for obstacles before operating in a new area. Never

attempt to operate over large obstacles, such as rocks or fallen trees. Always follow proper procedures when operating over obstacles as described in this manual.

• Always be careful of skidding or sliding. On slippery surfaces like

ice, travel slowly and use extra caution to reduce the chance of skidding or sliding out of control.

• Avoid operating the ATV through deep or fast-flowing water. If it's

unavoidable, travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. Test the brakes after

leaving water. If necessary, apply them lightly several times to allow friction to dry out the pads.

SAFETY

Rider Safety

• Always check for obstacles or people behind the ATV before operating in reverse. Be aware that a passenger can obstruct your view. When it's safe to proceed in reverse, move slowly and avoid turning at sharp angles.

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

• Never modify an ATV through improper installation or use of accessories.

• Never exceed the stated load capacity for your ATV. 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.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Consumer Product Safety Commission at 1-800-638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-

3764.

SAFETY

Rider Safety

Equipment Modifications

We are concerned for the safety of our customers and for the general public. Therefore, we strongly recommend that consumers do not install on a Polaris ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes. Any modifications to the original equipment of the vehicle create a substantial safety hazard and increase the risk of bodily injury.

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

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

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

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN HAPPEN The risk of an accident is greatly increased if the

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

HOW TO AVOID THE HAZARD Beginning and inexperienced operators should

complete the ATV RiderCourse Polaris through the SVIA. They should then regularly practice the skills learned in the course and the operating techniques described in the Owner's Manual.

For more information about the ATV RiderCoursesm contact ATV Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN HAPPEN Severe injury and/or death could occur if a child under the minimum age

recommendation operates this ATV or rides as a passenger. Even though a child may be within the recommended age group for operating

some ATVs, he/she may not have the skills, abilities, or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury.

HOW TO AVOID THE HAZARD No one under the age of 16 should operate a Polaris ATV. Never allow

anyone under 12 years of age to ride as a passenger on this 2-up ATV.

offered by

WARNING

Rider Safety

WARNING

POTENTIAL HAZARD Operating with more than one passenger. WHAT CAN HAPPEN Passengers affect balance and steering and

increase the risk of losing control, which can result in severe injury or death.

HOW TO AVOID THE HAZARD Never operate the 2-up ATV with more than

one passenger.

WARNING

POTENTIAL HAZARD Carrying a passenger in the cargo box. WHAT CAN HAPPEN A passenger riding in the cargo box could fall

from the vehicle unexpectedly or may contact moving components, both of which can result in severe injury or death.

HOW TO AVOID THE HAZARD Never allow a passenger to ride in the cargo

box.

SAFETY

WARNING

POTENTIAL HAZARD Operating an ATV on paved surfaces, including

sidewalks, paths, parking lots, and driveways. WHAT CAN HAPPEN ATV tires are designed for off-road use.

Operating on paved surfaces may adversely affect the handling of the ATV and could result in loss of control, accident, and/or injury.

HOW TO AVOID THE HAZARD Avoid operating the ATV on pavement. If it's

unavoidable, travel slowly and avoid sudden turns or stops.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV on public streets,

roads or highways. WHAT CAN HAPPEN The ATV could collide with another

vehicle. HOW TO AVOID THE HAZARD Never operate the ATV on any public

street, road or highway, including dirt and gravel roads. In many states it's illegal to operate ATVs on public streets, roads and highways.

WARNING

POTENTIAL HAZARD Riding an ATV without wearing an

approved helmet, eye protection and protective clothing.

WHAT CAN HAPPEN Riding an ATV without an approved

helmet increases the risk of a severe head injury or death in the event of an accident.

Riding without eye protection could result in an accident and could increase the chance of a severe injury in the event of an accident.

HOW TO AVOID THE HAZARD Always be sure operator and passenger wear an approved helmet that fits

properly. A passenger's helmet should have a rigid chin guard. Always be sure operator and passenger wear eye protection (goggles or face

shield), gloves, boots, a long-sleeved shirt or jacket, and long pants.

Rider Safety

WARNING

POTENTIAL HAZARD Operating the ATV after consuming alcohol or

drugs. WHAT CAN HAPPEN Consumption of alcohol and/or drugs could

seriously affect operator judgment. Reaction time may be slower and operator balance and perception could be affected.

Consuming alcohol and/or drugs before or while operating an ATV could result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD Never consume alcohol or drugs before or while operating an ATV.

WARNING

POTENTIAL HAZARD Operating the ATV at excessive

speeds. WHAT CAN HAPPEN Excessive speed increases the

operator's chance of losing control of the ATV, which can result in an accident causing severe injury or death.

HOW TO AVOID THE HAZARD Never operate at excessive

speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Attempting jumps and other stunts. WHAT CAN HAPPEN Attempting stunts increases the chance of

an accident, including an overturn. HOW TO AVOID THE HAZARD Never attempt jumps or other stunts.

Avoid exhibition driving.

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the ATV. WHAT CAN HAPPEN Poor maintenance increases the possibility of

an accident or equipment damage. HOW TO AVOID THE HAZARD Always inspect your ATV before each use to

make sure it's in safe operating condition. Always follow the inspection and maintenance

procedures and schedules described in the owner's manual.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Removing hands from the handlebars or

feet from the footrests during operation. WHAT CAN HAPPEN Removing even one hand or foot can

reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.

If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.

HOW TO AVOID THE HAZARD Always keep both hands on the handlebars and both feet on the footrests of

the ATV during operation. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating the ATV on unfamiliar terrain. WHAT CAN HAPPEN Unfamiliar terrain may contain hidden

rocks, bumps, or holes that could cause loss of control or overturn.

HOW TO AVOID THE HAZARD Travel slowly and use extra caution

when operating on unfamiliar terrain. Always be alert to changing terrain conditions.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Failure to use extra caution when

operating on excessively rough, slippery or loose terrain.

WHAT CAN HAPPEN Operating on excessively rough,

slippery or loose terrain could cause loss of traction or loss of control, which could result in an accident or overturn.

HOW TO AVOID THE HAZARD Do not operate on excessively rough, slippery or loose terrain until you've

learned and practiced the skills necessary to control the ATV on such terrain. Always use extra caution on rough, slippery or loose terrain.

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN HAPPEN Improper turns could cause loss of control and

lead to a collision or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for turning as

described in the owner's manual. Practice turning at slow speeds before

attempting to turn at faster speeds. Never turn at excessive speed.

SAFETY

>15°

Rider Safety

WARNING

POTENTIAL HAZARD Operating on excessively steep hills. WHAT CAN HAPPEN The vehicle may overturn. HOW TO AVOID THE HAZARD Never operate on hills too steep for

the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees.

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN HAPPEN Improper hill climbing could cause loss

of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for

climbing hills as described in the owner's manual. See page 73.

If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 49.

Always check the terrain carefully before ascending any hill. Never climb hills with excessively slippery or loose surfaces. Shift body weight uphill. A passenger should also shift body weight uphill. Never open the throttle suddenly while traveling uphill. The ATV could flip

over backwards. Never go over the top of any hill at high speed. An obstacle, a sharp drop, or

another vehicle or person could be on the other side of the hill. Never operate this ATV in TURF mode while operating on a hill or other

irregular terrain. See page 47. Switch the AWD switch out of TURF mode and into AWD mode when

ascending a hill.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Traveling downhill improperly. WHAT CAN HAPPEN Improperly descending a hill could

cause loss of control or overturn. HOW TO AVOID THE HAZARD Always follow proper procedures for

traveling down hills as described in the owner's manual. See page 75.

If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 49.

Always check the terrain carefully before descending a hill. Never operate this ATV in TURF mode while operating on a hill or other

irregular terrain. See page 47. Always descend a hill with the transmission in forward gear. Do not descend

a hill with the transmission in neutral. Shift body weight uphill. A passenger should also shift body weight uphill. Never travel down a hill at high speed. Avoid traveling down a hill at an angle, which would cause the vehicle to lean

sharply to one side. Travel straight down the hill when possible.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and turning on

hills. WHAT CAN HAPPEN Improperly crossing or turning on hills

could cause loss of control or overturn. HOW TO AVOID THE HAZARD Never attempt to turn the ATV around on

any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 76. Use extra caution when turning on any hill.

Do not cross a hillside with a passenger on board. Avoid crossing the side of a steep hill.

When crossing the side of a hill:

Always follow proper procedures as described in the owner's manual. Avoid hills with excessively slippery or loose surfaces. Shift your weight to the uphill side of the ATV.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards or

improperly dismounting while climbing a hill.

WHAT CAN HAPPEN The vehicle could overturn. HOW TO AVOID THE HAZARD Maintain steady speed when

climbing a hill. If your ATV is equipped with Active

Descent Control, always engage AWD before ascending a hill. See page 49.

If all forward speed is lost:

Lean forward to keep body weight uphill. A passenger should also lean uphill. Apply the single lever brakes. Lock the parking brake when fully stopped. Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator may dismount.

Turn the ATV around and remount, following the procedure described in the owner's manual. See page 76.

If the ATV begins rolling backwards:

Keep operator and passenger body weight uphill. Never apply engine power. Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually. When fully stopped, apply the foot brake as well, and then lock the parking

brake. Dismount on the uphill side of the vehicle, or on the left if the vehicle is

pointing straight uphill. Have a passenger dismount first, then the operator may dismount.

Turn the ATV around and remount, following the procedure described in the owner's manual. See page 76.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN HAPPEN Operating over obstacles could cause

loss of control or overturn. HOW TO AVOID THE HAZARD Before operating in a new area, check for

obstacles. Avoid operating over large obstacles

such as rocks and fallen trees when possible. If unavoidable, use extreme caution and always follow proper procedures as outlined in the owner's manual. Always have a passenger dismount before operating over an obstacle that could cause a fall from the vehicle or vehicle tipover.

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN HAPPEN Skidding or sliding can cause loss of

control. If the tires regain traction unexpectedly,

the ATV could overturn. HOW TO AVOID THE HAZARD On slippery surfaces such as ice, travel

slowly and use extra caution to reduce the chance of skidding or sliding out of control.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or

fast-flowing water. WHAT CAN HAPPEN Tires may float, causing loss of traction

and loss of control, which could lead to an accident or overturn.

HOW TO AVOID THE HAZARD Avoid operating the ATV through deep

or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 78), travel slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

Wet brakes may have reduced stopping ability. Always test the brakes after leaving water. If necessary, apply them several times to let friction dry out the pads.

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN HAPPEN The ATV could collide with an obstacle

or person, resulting in severe injury. HOW TO AVOID THE HAZARD Before shifting into reverse gear,

always check for obstacles or people behind the ATV. When it's safe to proceed, back slowly.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires,

or with improper or uneven tire pressure.

WHAT CAN HAPPEN Use of improper tires, or operation of

the ATV with improper or uneven tire pressure, could cause loss of control or accident.

HOW TO AVOID THE HAZARD Always use the size and type of tires

specified for the ATV in the owner's manual. Always maintain proper tire pressure as described in the owner's manual and

on safety decals.

WARNING

POTENTIAL HAZARD Operating the ATV with improper modifications. WHAT CAN HAPPEN Improper installation of accessories or modification of the ATV may cause

changes in handling, which could lead to an accident. HOW TO AVOID THE HAZARD Never modify the ATV through improper installation or use of accessories. All

parts and accessories added to the vehicle must be genuine Polaris Industries Inc. or equivalent components designed for use on this ATV and should be installed and used according to approved instructions. See your authorized Polaris ATV dealer for more information.

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing

cargo improperly. WHAT CAN HAPPEN Overloading and towing can cause

changes in vehicle handling, which could lead to loss of control or an accident.

HOW TO AVOID THE HAZARD Never exceed the stated load capacity for

this ATV. Cargo should be properly distributed and

securely attached. Reduce speed when carrying cargo or pulling a trailer. Allow a greater

distance for braking. Always follow the instructions in the owner's manual for carrying cargo or

pulling a trailer. See page 64. Always follow the instructions in the owner's manual for operating with a

passenger. See page 70.

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN HAPPEN Severe injury or death can result if

the ATV and/or riders fall through the ice.

HOW TO AVOID THE HAZARD Never operate the ATV on a frozen

body of water.

SAFETY

Rider Safety

WARNING

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

WARNING

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control, which could result in severe injury or death. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

WARNING

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

WARNING

Leaving the keys in the ignition can lead to unauthorized use of the vehicle resulting in serious injury or death. Always remove the ignition key when the vehicle is not in use.

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Worklight

Switch

(if equipped)

Main Key Switch

Engine

Stop Switch

Headlight

Switch

AWD Switch

Switches

WARNING

Activating the override switch while the throttle is open can cause loss of control, resulting in severe injury or death. Do not activate the override switch while the throttle is open.

Mode/Reverse Override Switch

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

NOTE: The override switch also allows activation of All Wheel Drive in

reverse, if the AWD switch is on. This switch is also used to toggle through the modes of the rider information center. See page 52.

FEATURES AND CONTROLS

OFF OFFRUN

Switches

Engine Stop Switch

Move the stop switch either left or right to the OFF position to stop the engine quickly. The engine will not start or run when the switch is off.

NOTE: Both the main switch and the engine stop switch will shut off all electri-

Main Key Switch

Use the main key switch to start the engine. See page 63 for starting procedures.

Worklight Switch

Use the worklight switch (if equipped) to turn the worklight on or off. The worklight is located at the rear of the vehicle. Turn the light on while loading and unloading cargo in low light situations. Turn the worklight off when driving.

Headlight Switch

Use the headlight switch to turn the lights on and off and to change the lights from high beam to low beam.

NOTE: The lights won't work unless the key is in the ON position and the

cal power to the vehicle, including lights.

engine stop switch is in the RUN position.

WARNING

Operating the ATV on streets or roads, especially in darkness, could result in an accident and serious injury or death.

Your ATV is not equipped with highway-approved lights. It's designed for and must be used for off-road use only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness.

FEATURES AND CONTROLS

Throttle Lever

WARNING

Operating an ATV with sticking or improperly operating throttle controls could cause an accident and lead to severe injury or death.

Never start or operate an ATV with a sticking or improperly operating throttle. Always contact your dealer for service if throttle problems arise.

Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.

Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.

This ATV is equipped with Polaris Electronic Throttle Control (ETC), which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, the engine will stop, and power to the rear wheels will cease.

WARNING

Modifications to the ETC could result in failure to perform as designed, which could result in severe injury or death. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is properly installed to the ETC.

FEATURES AND CONTROLS

Brake Lever

Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.

Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.

WARNING

Operating the ATV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever.

FEATURES AND CONTROLS

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

Check the brake fluid in the master cylinder before each ride. The fluid level can be seen through an indicator window on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.

NOTE: When checking the fluid

If the fluid level is low add DOT 4 brake fluid only. See page 143 for the part numbers of Polaris products.

An over-full master cylinder may cause brake drag or brake lock-up, which could result in serious injury or death. Maintain brake fluid at the recommended level. Do not overfill.

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

level, the ATV must be on level ground with the handlebars straight.

WARNING

FEATURES AND CONTROLS

Parking Brake

WARNING

Operating the ATV while the parking brake is engaged could result in an accident and serious injury or death. Always check to be sure the parking brake is disengaged before operating.

Locking the 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. It will return to its unlocked position.

Important Safeguards

• The parking brake may relax if left on for a long period of time.

Always block the wheels to prevent rolling.

• Always block the wheels on the downhill side of the A TV if leaving it

parked on a hill. Another option is to park the ATV in a sidehill position.

• Never depend on the parking brake alone if the ATV is parked on a

hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

Auxiliary Foot Brake

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake.

NOTE: Since this is a rear brake only, it will not be as effective as the all-wheel

Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death. Never back down a hill.

Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.

The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.

NOTE: If the rear wheels slide while

Brake Fluid Level

Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat. Maintain the fluid level between the maximum and minimum marks.

single lever system.

WARNING

using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

FEATURES AND CONTROLS

Gear

Selector

Fuel

Ta n k

Cap

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

Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.

CAUTION

Shifting gears with the engine speed above idle or while the vehicle is moving could cause transmission damage. To change gears, stop the vehicle, and with the engine idling, move the lever to the desired gear.

Belt Life

T o extend belt life, use low forward gear in heavy pulling situations and when operating at less than seven miles per hour for extended periods of time.

Fuel Filter

The in-line fuel filter is located under the rubber service cover inside the front box. Have your dealer replace the filter after every 200 hours of operation and any time the fuel becomes contaminated with dirt or debris. Do not attempt to clean the fuel filter.

Fuel Tank Cap

Remove the fuel tank cap to add fuel to the fuel tank. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane. Do not use E-85 fuel.

FEATURES AND CONTROLS

Recoil Starter

Handle

Recoil Starter (500 EFI)

If the battery is too weak to start the engine, use the recoil starter. Follow the starting procedures on page 63, cranking the engine with the recoil starter instead of the main key switch.

1. Grasp the recoil starter rope

handle tightly.

2. Pull slowly so you can feel

the engine strokes.

NOTE: The rope will be harder to pull when the engine is on a compression

3. Allow the recoil rope to rewind into the recoil assembly, then pull

4. Repeat all steps until the engine starts.

5. Make sure the handle is fully seated on the housing.

Extending the recoil starter rope until it stops can cause damage to the recoil assembly. Do not extend the starter rope so far that it stops.

If the starter rope handle is not seated properly, water may enter the recoil housing and damage components. Make sure the handle is fully seated on the recoil housing, especially when traveling in wet areas.

stroke. When a compression stroke is found, continue pulling the rope just until the engine rolls past the stroke, then stop pulling immediately.

the rope abruptly and forcefully to start the engine.

CAUTION

FEATURES AND CONTROLS

AWD

Switch

All Wheel Drive (AWD) System

The All Wheel Drive system is controlled by the AWD switch. When the switch is on 2X4 (center position), the ATV is in twowheel drive at all times. When the switch is on AWD (left position), the ATV is in all wheel drive and the AWD indicator light in the instrument cluster will be on.

When in AWD, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in AWD.

NOTE: The override switch allows activation of AWD in reverse if the AWD

When the switch is on TURF (right position), the differential is open, allowing the inside wheel to rotate independently from the outside wheel during turns. Operate this vehicle in TURF mode only to protect smooth, level surfaces from tire damage. Otherwise, switch out of TURF mode.

switch is on. See page 38.

WARNING

Operating in TURF mode when on sloped, uneven, or loose terrain could cause loss of control and result in serious injury or death. One rear wheel may slip and lose traction or may lift up and grab when it touches the ground again.

DO NOT operate in TURF mode when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain conditions such as sand, gravel, ice, snow, obstacles, and water crossings.

Switch the All-Wheel Drive (AWD) system out of TURF mode whenever it is not required.

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

Engaging AWD

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

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

CAUTION

Switching to AWD (or from TURF to 2X4) while the rear wheels are spinning may cause severe drive shaft and gearcase damage. Always switch to AWD (or to TURF from 2X4) while the rear wheels have traction or are at rest.

FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system (if equipped) allows engi ne braking to all fou r wheels when the vehicle descends a hill or incline. If your ATV is equipped with Active Descent Control, always engage AWD before ascending or descending a hill.

Engaging Active Descent Control

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

• The AWD switch must be in the AWD position

• Vehicle speed must be 15 mph (24 km/h) or less

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

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

• The AWD switch is moved to the 2X4 position

• Vehicle speed exceeds 15 mph (24 km/h)

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Dump Lever

Passenger

Backrest

Operator Backrest Latches

(view from front)

Locked

Unlocked

Passenger Seat

Always make sure the passenger seat lock-out is functioning properly before operating with a passenger.

Do not operate the vehicle with the seat in the 2-up position when operating without a passenger. Always retu rn the seat to the 1-up position for single-rider operation.

Never carry cargo in the rear box when operating the ATV in the 2-up mode with a passenger.

Seat Conversion

1. Make sure the cargo box dump lever is securely latched.

2. Rotate both operator backrest latches 1/4 turn to release the locks.

3. Tilt the backrest slightly forward.

4. Pull the passenger backrest upward from the bed of the cargo box.

FEATURES AND CONTROLS

Passenger

Backrest

Adjustment

Latch

Locked

Passenger Seat

Seat Conversion

5. Lift the adjustment latch at the top of the passenger backrest. Raise

the backrest to the desired position. Release the latch, making sure it locks into one of the three operating positions.

NOTE: The backrest must be moved out of the lowest position before it can be

6. Lower the operator

7. Test the passenger seat

NOTE: If the lock-out is not working properly, do not allow a passenger to ride

8. To return the vehicle to single-rider

secured in the upright position. The lowest position is for seat storage only. Do not leave the backrest in the lowest position. Always adjust the backrest to one of the three operating positions.

backrest to create the passenger seat. Two retaining pins under the seat should fit into the two grommets on the seat base.

lock-out by attempting to release the cargo box dump lever. If the dump lever releases, the seat is not secure. Repeat the setup procedure.

the vehicle. See your Polaris dealer for service.

operation, reverse all steps. Always lower the passenger backrest to the lowest position before folding it down into the cargo box. Turn the operator backrest latches 1/4 turn to secure the locks.

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph. Refer to page 38 for additional information.

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

when a warning condition exists.

CAUTION

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.

FEATURES AND CONTROLS

345

Instrument Cluster

Rider Information Center

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

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

1. Gear Indicator - This

2. AWD Indicator - This

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

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

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

9. Mode Indicator

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.

indicator displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park

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

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

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 38.

NOTE: The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

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

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

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally.

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

Clock Mode

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

55.

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

of changes in humidity, temperature and elevation.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

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

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

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

Release the button.

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

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

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

onds, until the minute display flashes.

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

7. Use the same procedure to reset the minutes.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

AWD Diagnostic Screen

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

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 57.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

3. Press and hold the mode button for about 7 seconds, until either ON

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

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

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

the hours cycle back to zero.

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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

See page 59 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in

PARK. Stop the engine. Turn the key switch to the ON position.

2. Turn the key switch off and

on three times in less than five seconds. The word “WAIt” will appear on the screen.

3. The Check Engine icon will blink once, pause, then blink twice

(blink code 12) to begin the diagnostic sequence. The EFI module is now searching for blink codes. If a code exists, the Check Engine icon will flash the code.

4. Count the number of times the Check Engine icon flashes.

Example: For the two blink codes 42 and 36, the Check Engine icon will flash 4 times, pause, then flash 2 times (code 42), then pause longer, blink 3 times, pause, and blink 6 times (code 36).

5. A code 61 will signal the end of the sequence. If no blink codes are

found, only codes 12 and 61 will appear during the sequence.

NOTE: The word “WAIt” will remain on the screen through this entire process.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Failure Description

Code

12 BEGIN SEQUENCE

45 Barometric Pressure/Manifold Air Pressure Sensor Low

46 Barometric Pressure/Manifold Air Pressure Sensor High

41 Air Temp Sensor Low Voltage

41 Air Temp Sensor High Voltage

42 Engine Coolant Temp Low Voltage

42 Engine Coolant Temp High Voltage

22 Throttle Position Sensor Low

22 Throttle Position Sensor High

51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground

51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery

52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground

52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery

56 Fuel Pump: Open Load/Short-to-Ground

56 Fuel Pump: Shorted Load/Short-to-Battery

44 Crank Position Sensor Circuit Fault

36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

31 System Voltage Low

31 System Voltage High

55 MIL Circuit: Open Load/Short-to-Ground

55 MIL Circuit: Shorted Load/Short-to-Battery

58 Fan Circuit: Open Load/Short-to-Ground

58 Fan Circuit: Shorted Load/Short-to-Battery

47 IAC Stepper Motor: Open Load

47 IAC Stepper Motor: Short-to-Ground

61 END SEQUENCE

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and 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.

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

WARNING

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm.

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

OPERATION

Break-In Period

The break-in period for your new Polaris ATV is the first ten hours of operation, or the time it takes to use the first two full tanks of gasoline. 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.

CAUTION

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.

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 45.

2. Check the engine oil level on the dipstick. See page 90. 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 62.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours or one month.

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.

OPERATION

Pre-Ride Checklist

WARNING

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

Item Remarks Page

Passenger seat lock-out Ensure proper operation 50

Brake system/lever travel Ensure proper operation 41

Brake fluid Ensure proper level 42

Auxiliary brake Ensure proper operation 44

Front suspension Inspect, lubricate if necessary 89

Rear suspension Inspect, lubricate if necessary 89

Steering Ensure free operation -

Tires Inspect condition and pressure 107

Wheels/fasteners Inspect, ensure fastener tightness 107

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 45

Coolant level (if applicable) Ensure proper level 102

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 40

Indicator lights/switches Ensure operation 38

Engine stop switch Ensure proper operation 39

Air filter, pre-filter Inspect, clean 109

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

Brake light/taillight Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 100

tric grease when lamp is replaced

protective clothing

104

108

103

138

112

115

OPERATION

Starting the Engine

WARNING

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

1. Position the vehicle on a level surface.

2. Place the transmission in PARK.

3. Lock the parking brake.

NOTE: The starter interlock will prevent the engine from starting if the trans-

4. Sit on the vehicle and move the engine stop switch to RUN.

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

5. Turn the ignition key past the ON position to engage the starter.

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

mission is in gear and the brake is not engaged.

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

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

CAUTION

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 ATV 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

Hauling Cargo

WARNING

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

Never exceed the stated load capacity for this vehicle. Never carry cargo in the rear box when operating the ATV in the 2-up mode

with a passenger. REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO. REDUCE SPEED AND CARGO to maintain stable driving conditions when

operating over rough or hilly terrain. WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as

low as possible. Carrying a high load raises the center of gravity and creates a less stable operating condition. Reduce load weight when cargo is high. When handling off-centered loads that cannot be centered, secure the load and operate with extra caution.

SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift and create unstable operating conditions, which could result in loss of control of the vehicle. Always be sure that the cargo bed is lowered and latched before moving the vehicle.

USE EXTREME CAUTION when operating with loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing the machine to overturn.

BALANCE LOADS proportionally between the front rack and cargo bed, but do not exceed the stated load capacity. Carrying a load on only the front rack or cargo bed may cause an imbalanced condition and increases the possibility of vehicle overturn.

USE EXTREME CAUTION when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.

Always attach the tow load to the hitch point. DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The

vehicle should never exceed 10 mph (16 kph) while towing a load on a level surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.

DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.

OPERATION

Hauling Cargo

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warning labels on the vehicle, and never exceed the weight capacities outlined in the specifications section of the owner's manual and on the

safety decals. Cargo weight should be

mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo weight to maintain stable driving conditions. Do not obstruct the headlight beam with cargo. Use low forward gear when hauling or towing heavy cargo to extend belt life.

1. Always load the cargo box with the load as far forward as possible.

2. Always operate the vehicle with extreme caution whene ver hauling or towing loads. Balance, handling, and control may be affected.

3. Slow down.

4. Make sure the cargo box dump latch is securely latched before loading and operating. Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured.

OPERATION

Maximum

6 3/4" (17 cm)

Hauling Cargo

Towing Loads

Always attach a towed load to the hitch point. 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.

CAUTION

Using an improper hitch or exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 6 3/4" (17 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris-approved (or equivalent) accessories designed for ATV use.

Maximum Towing Capacities

Do not exceed the following maximum capacities when towing. Avoid towing on inclines.

500 EFI 800 EFI

Maximum Towed Load (Level Ground) 1225 lbs. (557 kg) 1500 lbs. (680 kg)

Maximum Vertical Hitch Weight 120 lbs. (55 kg) 150 lbs. (68 kg)

OPERATION

Dump Box

Release

Latch

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo box. Do not attempt to dump or

unload the vehicle while parked on an incline.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Dismount the vehicle.

5. Lower the tailgate.

WARNING

If cargo weight is placed toward the rear of the cargo box, the load may dump unexpectedly and cause serious injury. When loading cargo, always position the weight as far forward and as low as possible.

6. Pull the cargo box release lever upward.

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

8. Lower the cargo box and make sure the release latch is secured.

9. Secure the tailgate.

WARNING

Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle. The cargo box could close unexpectedly and injure the driver. The rear tires will also catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions.

Never operate this vehicle with the cargo box in the raised position.

OPERATION

Driving Procedures

1. Wear protective ridin g ge ar. See page 12.

2. Perform the pre-ride inspection. See page 62.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

6. Sit upright with both feet on the footrests and both hands on the handlebars.

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

8. Shift the transmission into gear.

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

10. Release the parking brake.

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.

OPERATION

Turning the Vehicle

Both rear wheels drive equally at all times, except when operating in TURF mode. This means that the outside wheel must travel a greater distance than the inside wheel when turning, and the inside tire must slip traction slightly.

1. Slow down.

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

3. Steer in the direction of the turn.

4. Keep both feet on the footrests.

5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest.

NOTE: This technique alters the balance of traction between the rear wheels,

6. The same leaning technique should be used for turning in reverse.

NOTE: Practice making turns at slow speeds before attempting to turn at

allowing the turn to be made smoothly.

faster speeds.

WARNING

Turning at sharp angles or at excessive speeds can result in vehicle overturn and lead to serious injury. Avoid turning at sharp angles. Never turn at high speeds.

OPERATION

Driving with a Passenger

1. Make sure the passenger is at least 12 years of age and is tall enough to comfortably reach the footrests and grab handles.

2. Make sure the passenger

is wearing appropriate riding gear, including an approved helmet with a rigid chin guard. See page 12.

3. Perform the pre-ride

inspection. See page 62.

4. Convert the seat for 2-up

riding. See page 50. Make sure the passenger seat lock-out is functioning properly.

5. Lock the parking brake.

6. 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.

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

8. Do not carry more than one passenger.

9. Slow down. C on t rol may be more difficult with a passenger on

board. Allow more time and distance for braking.

OPERATION

Driving with a Passenger

10. 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.

11. Do not cross a hillside with a passenger on board. See page 74.

12. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.

13. 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

Driving on Slippery Surfaces

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

1. Slow down when entering slippery areas.

2. Engage AWD before

wheels begin to lose traction.

3. Maintain a high level of

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

4. Correct a skid by turning the handlebars in the direction of the skid

and shifting your body weight forward.

CAUTION

Severe damage to drive train may occur if the AWD is engaged while the wheels are spinning. Always allow the rear wheels to stop spinning before engaging AWD, or engage AWD before wheels begin to lose traction.

WARNING

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

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

OPERATION

15° Maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. If your ATV is equipped with Active Descent Control, always engage AWD before ascending a hill. See page 49.

2. Drive straight uphill.

3. Avoid steep hills (15° maximum).

4. Keep both feet on the footrests.

5. Shift body weight uphill.

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

7. Remain alert and be prepared to take emergency action. This may

include quick dismounting of the vehicle.

8. If the vehicle stalls while climbing a hill, never back it down the

hill! Apply the hand brake. If a passenger is on board, ask the passenger to dismount. Use the K-turn to turn around. See page 76.

WARNING

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

Avoid climbing steep hills (15° maximum). Use extreme caution when operating on hills, and follow proper operating

procedures outlined in the owner's manual.

OPERATION

Driving on a Sidehill (Sidehilling)

WARNING

Improperly crossing hills or turning on hills can result in loss of control or vehicle overturn, resulting in severe injury or death. Avoid crossing the side of a hill when possible. Do not cross a hillside with a passenger on board. Follow proper procedures as outlined in the owner's manual.

Sidehilling can be dangerous and should be avoided if at all possible. If you encounter a situation where sidehilling is necessary, follow these precautions:

1. Slow down.

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

3. Lean into the hill, transferring your upper body weight toward the hill while keeping your feet on the footrests.

4. Steer slightly into the hill to maintain vehicle direction.

NOTE: If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

OPERATION

15° Maximum

Driving Downhill

WARNING

Excessive speed when traveling downhill can cause loss of control and serious injury or death. Slow down.

Applying the brakes too firmly may cause the rear wheels to lock, which could result in loss of control and serious injury or death. Apply the brakes gradually.

When driving downhill, follow these precautions:

1. If your ATV is equipped with Active Descent Control, always engage AWD before descending a hill. See page 49.

2. Always descend a hill with the transmission in forward gear . Do not

descend a hill with the transmission in neutral.

3. Slow down.

4. Proceed directly downhill.

5. Shift body weight uphill.

6. Apply the brakes slightly to aid in slowing.

NOTE: Before operating your ATV, learn how to use the auxiliary brake for

emergency situations (if single-lever brakes become inoperable).

OPERATION

8 ft. (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.

OPERATION

Turning Around on a Hill (K-Turn)

1. Stop and lock the parking brake while keeping body weight uphill.

2. If your ATV is equipped with Active Descent Control, engage

AWD. See page 4 9.

3. Leave the transmission in forward and shut off the engine.

4. If a passenge r is on board, ask the passe nger 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.

5. Staying uphill of the vehicle , turn the handlebars full left.

6. While holding the brake lever, release the parking brake lock and

slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.

7. Lock the parking brake. Remount the vehicle from the uphill side,

keeping body weight uphill.

NOTE: A passenger should not remount until the vehicle returns to firm, level

8. Start the engine with the transmission still in forward.

9. Release the parking brake and proceed slowly, controlling speed

ground.

with the brake lever, until the vehicle is on more level ground.

OPERATION

Maximum

Depth

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:

1. Determine water depths and current before crossing.

2. Choose a crossing where both banks have gradual inclines.

3. Proceed slowly, avoiding rocks and obstacles.

4. After crossing, dry the brakes by applying light pressure to the lever until braking action is normal.

OPERATION

Driving Through Water

After running the vehicle in water, it's critical to have it serviced as outlined in the maintenance chart. See page 85. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings.

CAUTION

Major engine damage can result if the vehicle is not thoroughly inspected after operation in water. Perform the services outlined in the maintenance chart.

If your vehicle becomes immersed or is operated in water that exceeds the footrest level, take it to your dealer for service before starting the engine.

NOTE: Avoid operating the vehicle through deep or fast-flowing water. If you

cannot avoid water that exceeds the recommended maximum depth, go slowly, balance your weight carefully, avoid sudden movements, and maintain a slow and steady forward motion. Do not make sudden turns or stops, and do not make sudden throttle changes.

If your vehicle becomes immersed, and it's impossible to take it to a dealer before starting it, follow the steps described on page 118. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving Over Obstacles

1. Be alert! Look ahead and learn to read the terrain you're traveling

on. Be constantly alert for hazards such as logs, rocks and low hanging branches.

2. Avoid operating over large obstacles such as rocks and fallen trees when possible. If unavoidable, use extreme caution.

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

WARNING

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

OPERATION

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 PARK.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side.

OPERATION

Driving in Reverse

WARNING

Failure to use caution when operating in reverse can result in serious injury or death. Before shifting into reverse, always check for obstacles or people behind the vehicle. When it's safe to proceed, back slowly.

Do not use the override switch unless additional power is required for vehicle movement. Use with caution.

Avoid backing on inclines, and avoid turning at sharp angles.

CAUTION

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. Operate the throttle just enough to maintain a desired speed

OPERATION

Driving in Reverse

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. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

NOTE: Your Polaris ATV is equipped with a reverse speed limiter. Use the

override button with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Apply just enough throttle to maintain a desired speed.

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

Your Polaris vehicle has a spark arrestor that was tested and qualified to be in accordance with the USDA Forest Service Standard 5100-1C. Federal law requires that this spark arrestor be installed and functional when the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 8343. Violations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.

Crankcase Emission Control System

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

Exhaust Emission Control System

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

The emissions label is located on the recoil cover or air box cover.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002. This vehicle complies with European directives 97/24/EC and 89/336/

EEC.

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 154.

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

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.

you're not familiar with safe service and adjustment procedures, have a qualified dealer perform these operations.

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

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

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

Q Have an authorized Polaris dealer perform these services.

WARNING

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

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Passenger seat lock-out

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine oil level - Pre-Ride -

XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant (if applicable)

X ADC fluid

(ADC models)

Headlight/taillight/ worklight

(whichever comes first)

Hours Calendar Miles

-Pre-Ride -

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check level daily, add as

- Daily - Check operation; apply

(Km)

needed. See Pre-Ride Checklist on page 62.

as needed

coolant every 2 years

needed

dielectric grease if replacing lamps

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

Recoil housing (if applicable)

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

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

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

(if equipped)

X Transmission oil 25 H Monthly 250 (400) Inspect level; change yearly XEEngine breather

filter (if equipped)

X General

lubrication

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

Steering 50 H 6 M 500 (800) Lubricate

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

Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct

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

Cooling system (if applicable)

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

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

(whichever comes first)

Hours Calendar Miles

- Weekly - Inspect; replace as needed

- Weekly - Drain water as needed,

25 H Monthly 250 (400) Inspect level; change yearly

25 H Monthly 250 (400) Inspect; clean if needed

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

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

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

50 H 6 M 1000 (1600) Inspect coolant strength

(Km)

check often if operating in wet conditions

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Valve clearance 100 H 12 M 1000 (1600) Inspect; adjust

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

X Radiator

(if applicable)

X Cooling hoses

(if applicable)

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

Exhaust muffler/ pipe

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

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

Clutches (drive and driven)

Front wheel bearings

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

ADC fluid (ADC models)

Fuel filter 200 H 24 M 2000 (3200) Check for leaks around lines.

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

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use. E Emission-Related Service

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

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

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

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

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

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

(Km)

lines, filter, pump; replace lines every two years

surfaces

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

parts

Replace every 2 years, more often under extreme conditions.

when parts are replaced

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Items not listed in the chart should be lubricated at the General Lubrication interval.

NOTE: The a-arms and upper control arms are lubricated at the factory, and

Engine Oil Polaris Premium 4 Synthetic

Brake Fluid DOT 4 Only See page 42.

Transmission Oil Polaris AGL Synthetic

Demand Drive Fluid (Front Gearcase)

ADC Fluid Polaris ADC Fluid See page 100.

Front Prop Shaft Yoke Polaris Premium U-Joint

no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Method

0W40

Gearcase Lube

Demand Drive LT Premium Fluid

Lube

See page 90.

See page 98.

See page 99.

Grease fittings (3 pumps maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris Premium 4 All Season synthetic engine oil has been specially formulated for use in Polaris 4-cycle engines. It's a fully synthetic, high performance, multi-viscosity oil designed to provide the ultimate in lubrication performance and protection. See page 143 for the part numbers of Polaris products.

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

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

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

CAUTION

Mixing brands or using a non-recommended oil may cause serious engine damage. We recommend the use of Polaris Premium 4 synthetic oil or another 0W-40 API certified SH oil. Never substitute or mix oil brands.

Engine Oil

Dipstick

Safe

Add Oil

{

Safe Range

Oil Level (500 EFI)

Access the oil dipstick and fill tube from the left side of the ATV.

NOTE: A rising oil level between

checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.

1. Position the vehicle on a level surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the engine.

3. Remove the dipstick. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

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

6. Reinstall the dipstic k securely.

MAINTENANCE

Dipstick

Safe

Add Oil

{

Safe

Range

Check Level

on Top Side

Engine Oil

Oil Level (800 EFI)

Access the oil dipstick and fill tube from the left side of the ATV.

1. Position the vehicle on a level surface.

2. Lift the lever lock to remove

the dipstick. Wipe it dry with a clean cloth.

3. Reinstall the dipstick com-

pletely, but do not lock it.

NOTE: The dipstick must be inserted

4. Remove the dipstick and check

NOTE: Due to the dipstick entry angle

5. After reinstalling the dipstick,

completely to keep the angle and depth of the stick consistent.

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

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

seat the lever lock.

MAINTENANCE

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

Engine Oil

Oil and Filter Change (500 EFI)

CAUTION

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

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85.

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drai n plug.

5. Place a drain pan under the oil tank.

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

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

NOTE: The sealing surfaces on drain

8. Reinstall the drain plug. Torque

9. Disconnect the lower oil deliv-

NOTE: The fitting threads must be sealed with LOCTITE PST 505 or PTFE

10. Reinstall the screen fitting and rotate the fitting clockwise a mini-

NOTE: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs.

11. Reattach the oil line.

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

to 14-17 ft. lbs. (19-23 Nm).

ery hose and remove the screen fitting from the oil tank. Clean the fitting.

seal tape.

mum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark on the tank.

(34 Nm).

MAINTENANCE

Engine Oil

Oil and Filter Change (500 EFI)

12. Place shop towels beneath the oil filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

13. Make sure the o-ring from the old filter is completely removed from the engine. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

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

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

16. Approximately one cup of engine oil will remain in the crankcase. To drain, remove the drain plug on the lower right side of the crankcase.

NOTE: The sealing surfaces on the drain plug and crankcase should be clean

17. Reinstall the drain plug.Torque to 14 ft. lbs. (19 Nm).

18. Remove the dipstick.

19. Add two quarts (1.9 l) of recommended oil. Reinstall the dipstick.

NOTE: If the sump is not drained, add about 1 3/4 quarts (1.6 l) initially.

20. Place the transmission in PARK.

21. Lock the parking brake.

22. Prime the oil pump using the procedure on page 95. Then stop

23. Check the oil level. Add oil as needed to bring the level to the upper

24. Dispose of used filter and oil properly.

and free of burrs, nicks or scratches.

the engine and inspect for leaks.

mark on the dipstick.

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

(5 cm)

Engine Oil

Oil and Filter Change (500 EFI)

Oil Pump Priming

This priming procedure must be performed whenever the oil hose connection between the oil tank and pump inlet has been disconnected.

1. Clamp or pinch off the vent line approximately 2" (5 cm) from the oil tank, between the end of the oil tank vent fitting and the vent line's pressure relief slit.

2. Start the engine. Allow it to idle

for 10-20 seconds.

3. Remove the vent line clamp. If the line is bled properly, you should

hear a rush of air, indicating that the line is properly primed and ready for operation.

NOTE: If you do not hear air, the line has not bled. Repeat the priming

procedure.

MAINTENANCE

Drain Plug Location

to front

Engine Oil

Oil and Filter Change (800 EFI)

CAUTION

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

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 85. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drain plug.

5. Place a drain pan under the crankcase.

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

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

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

8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).

free of burrs, nicks or scratches.

MAINTENANCE

Engine Oil

Oil and Filter Change (800 EFI

9. Place shop towels be neath the oil filter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it.

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

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

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

13. Remove the dipstick.

14. Add two quarts (1.9 l) of recommended oil.

15. Place the transmission in PARK.

16. Lock the parking brake.

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

18. Stop the engine.

19. Check for leaks.

20. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.

21. Dispose of used filter and oil properly.

Polaris Sporstman X2 800 EFI, Sportsman 500 X2, Sportsman 9920632, Sportsman 800 X2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual