Polaris Sportsmabn X2 500 EFI 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 1-800-342-3764 for assistance.

WELCOME

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

S Snowmobiles S All-terrain vehicles (ATVs) S RANGER utility vehicles S Victory motorcycles

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

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

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

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

Copyright 2005 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A.

2006 Sportsman X2 500 EFI Owner’s Manual P/N 9920361

TABLE OF CONTENTS

VEHICLE IDENTIFICATION NUMBERS 5.......

SAFETY 6...................................

CONTROLS 36...............................

FEATURES 43...............................

OPERAT ION 52..............................

EMISSION CONTROL SYSTEMS 73............

MAINTENANCE 74...........................

ADJUSTMENTS 115..........................

POLARIS PRODUCTS 117....................

TROUBLESHOOTING 118.....................

SPECIFICATIONS 122........................

WARRANTY 124.............................

MAINTENANCE LOG 130.....................

INDEX 132...................................

VEHICLE IDENTIFICATION NUMBERS

Record your ATV’s identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number:

Frame VIN (1):

Engine Serial Number (2):

Key Number (3):

31XX

SAFETY

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.

WARNING

S Never operate this vehicle on HILLS steeper than 15 degrees.

To prevent flipover on hilly terrain, when going up or down, use throttle and brakes gradually.

S Never operate this vehicle in TURF mode on irregular terrain,

including hills and obstacles.

S REVERSE operation can be dangerous even at low speeds.

Steering becomes difficult. To prevent flipover, avoid sudden braking or sharp turns.

S Use OVERRIDE for reverse speed limiter with caution. To prevent

loss of control, never activate override button with open throttle.

S When this vehicle is not in operation or unattended, place shift

in the park position.

7173948

SAFETY

Safety Decals and Locations

WARNING

Improper vehicle 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 op erate:

S without proper training or instruction S at speeds too fast for your skills, your passenger’s skills,

or the conditions

S on public roads -- a collision can occur with another vehicle S with more than one passenger -- passengers affect balance

and steering and increase risk of losing control

S with a passenger under the age of 12

THE OPERATOR MUST ALWAYS:

S use proper riding techniques to avoid vehicle overturns

on hills and rough terrain and in turns

S avoid paved surfaces -- pavement may seriously affect

handling and control

S reduce speed and use extra caution at all times when carrying a

passenger -- have passenger dismount when conditions require

S 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.

E1997, 2000 7173889

SAFETY

Safety Decals and Locations

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

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.

CARGO IS 1500 LBS. (680 kg)

7173900

ATTENTION

S Operation of this vehicle without the air filter element will

severely damage the engine.

S Clean pre-filter element often, more frequent cleaning required

in dusty conditions. Do not operate vehicle without pre-filter.

7172921

Safety Decals and Locations

WARNING

Operating this vehicle 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.

WARNING

SAFETY

7172588

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. Max. combined Front Rack and container Load 90 lbs. (41 kg).

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. Max. Box Load - 400 lbs. (181 kg)

7172569

SAFETY

Safety Decals and Locations

WARNING

PASSENGER SAFETY

To reduce the risk of SEVERE INJURY or DEATH.

PASSENGER

UNDER

NEVER CARRY A PASSENGER UNDER AGE 12

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

THE PASSENGER MUST ALWAYS:

S use an approved helmet and protective gear S securely grasp hand holds and plant feet firmly

on footrests

S tell operator to slow down or stop if

uncomfortable -- get off and walk if conditions require

NEVER CARRY

MORE THAN ONE

PASSENGER

NEVER RIDE AFTER

USING DRUGS OR

ALCOHOL

7174028

Safety Decals and Locations

WARNING

S Moving parts hazard under belt-clutch guard. To

prevent serious injury, do not operate vehicle with guard remov e d .

S 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.

NO STEP

SAFETY

7172563

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.

7172564

ALL WHEEL

DRIVE

SWITCH

Do not push s witch t o engage AWD if the rear wheels are spinning. This may cause severe drive shaft and clutch damage. See your Owner’s Manual.

7079780

MANUFACTURED BY: POLARIS IND. INC.

DATE:

VIN:

THIS VEHICLE IS AN ALL TERRAIN VEHICLE AND IS NOT INTENDEDFOR USE ON PUBLIC ROADS.

CE VÉHICULE EST UN VÉHICULE TOUT TERRAIN QUI NiEST PAS DESTINÉ À ÊTRE UTILISÉ SUR LES CHEMINS PUBLICS.

Canadian Certification Decal

7171492

TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND

HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55KG)

7174159

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

RiderCoursesmavailable 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 provided with 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

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 the ATV in your area.

We 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.

by calling ATV Enrollment Express at (800) 887-2887

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.

.Youwerealso

Know Your Vehicle

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.

SAFETY

Safe Riding Gear

Always wear clothing suited to the type of riding. ATV riding requires special protective clothing for comfort and to reduce the chance of injury.

1. Helmet

Your helmet is the most important piece of protective gear for safe riding. A helmet can prevent a severe head injury.

Select an approved helmet that meets or exceeds your state’s safety standards and bears either the Department of Transportation (DOT) label, the American National Standards Institute label (ANSI z90.1), or the Snell Memorial Foundation label.

A passenger’s helmet should have a rigid chin guard.

2. Eye Protection

Do not depend on sunglasses for proper eye protection. A pair of goggles or a helmet face shield offer the best protection for your eyes. They should be kept clean and be of shatterproof design (bearing the markings Z2.1 or VESC 8).

3. Gloves

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

4. Boots

The best footwear is a pair of strong over-the-calf boots with heels, like moto-cross boots.

5. 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 serious 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.

The f ollowing signal words and symbols appear in 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 personal 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 personal 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.

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

procedures described.

S 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 RiderCourse

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

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

rope or similar device.

S Never carry more than one passenger on this 2-up ATV. S Always make sure the passenger seat lock-out is functioning proper-

ly before carrying a passenger .

S Never permit a guest to operate the ATV unless the guest has read

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

S 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.

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

walks, driveways, parking lots, and streets.

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

a dirt or gravel road.

S Never ride 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.

S Never consume alcohol or drugs before or while riding an ATV.

. Contact ATV

SAFETY

Rider Safety

S Never operate at excessive speeds. Travel at speeds appropriate for

your skills, your passenger’s skills, and operating conditions.

S Never attempt wheelies, jumps or other stunts. S 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.

S Always travel slowly and use extra caution when operating on unfa-

miliar terrain. Be alert to changing terrain conditions.

S Never operate on excessively rough, slippery, or loose terrain. S Always follow proper turning procedures as described in this manu-

al. Practice turning at low speeds before attempting to turn at faster speeds. Do not turn at excessive speeds.

S Always have the ATV inspected by an authorized Polaris dealer if

it’s been involved in an accident.

S 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.

S Never operate on hills too steep for the ATV or for your abilities. S Never operate this ATV in TURF mode while operating on a hill or

other irregular terrain. See page 43.

S Always follow proper procedures for climbing hills. Check the ter-

rain carefully before ascending a hill. Never climb hills with excessively slippery or loose surfaces. Shift body 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.

S Always follow proper procedures for going downhill and for braking

on hills. Check the terrain carefully before you start down a hill. Shift body 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. Travel straight down the hill when possible.

S 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 body 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.

SAFETY

Rider Safety

S 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.

S 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.

S 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.

S 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.

S Always check for obstacles or people behind t he ATV before operat-

ing 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.

S Always use the size and type of tires specified for your ATV, and

always maintain proper tire pressure.

S Never modify an ATV through improper installation or use of acces-

sories.

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

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating this ATV without proper instruction. WHAT CAN 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 Beginning and inexperienced operators should complete the ATV

RiderCourse

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 RiderCourse Enrollment Express at (800) 887-2887 or visit www.atvsafety.org.

HAPPEN

HAZARD

offered by Polaris through the SVIA. They should

contact ATV

WARNING

POTENTIAL HAZARD Failure to follow the age recommendations for this ATV. WHAT CAN 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 No one under the age of 16 should operate this ATV. Never allow

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

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

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

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

HOW TO AVOID THE Never operate the 2-up ATV with more than one passenger.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Carrying a passenger in the cargo box. WHAT CAN 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 Never allow a passenger to ride in the cargo box.

HAPPEN

HAZARD

Rider Safety

WARNING

POTENTIAL HAZARD Operating an ATV on paved

surfaces, including sidewalks, paths, parking lots, and driveways.

WHAT CAN ATV tires are designed for off-road

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

HOW TO AVOID THE Avoid operating the ATV on pavement. If it’s unavoidable, travel

slowly and avoid sudden turns or stops.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV on

public streets, roads or highways.

WHAT CAN The ATV could collide

with another vehicle. HOW TO AVOID THE Never operate the ATV on any

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

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Riding an ATV without

wearing an approved helmet, eye protection and protective clothing.

WHAT CAN 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 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.

HAPPEN

HAZARD

Rider Safety

WARNING

POTENTIAL HAZARD Riding the ATV after consuming alcohol

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

could seriously affect operator (and passenger) judgment. Reaction time may be slower. Balance and perception could be affected.

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

HOW TO AVOID THE DO NOT drink alcohol or use drugs or medications before or

while driving the ATV or riding as a passenger.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating the ATV at

excessive speeds. WHAT CAN 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 Never operate at excessive speeds. Travel at speeds

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

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Attempting wheelies, jumps

and other stunts. WHAT CAN Attempting stunts increases

the chance of an accident, including an overturn.

HOW TO AVOID HAZARD

Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.

HAPPEN

THE

WARNING

POTENTIAL HAZARD Failure to inspect the ATV before operating. Failure to properly maintain the A TV. WHAT CAN Poor maintenance increases the possibility of an accident or

equipment damage. HOW TO AVOID THE 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.

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating on frozen bodies of water. WHAT CAN Severe injury or death can result if the ATV and/or the operator

fall through the ice. HOW TO AVOID THE Never operate the ATV on a frozen body of water.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Removing hands from the

handlebars or feet from the footrests during operation.

WHAT CAN 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 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.

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating the ATV on unfamiliar terrain.

WHAT CAN Unfamiliar terrain may

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

HOW TO AVOID THE Travel slowly and use extra caution when operating on unfamiliar

terrain. Always be alert to changing terrain conditions.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Failure to use extra

caution when operating on excessively rough, slippery or loose terrain.

WHAT CAN 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 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. Never operate this ATV in TURF mode while driving on uneven,

loose, or slippery terrain conditions. See page 43.

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Turning improperly. WHAT CAN Improper turns could cause loss of control and lead to a collision

or overturn. HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

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

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

HAPPEN

HAZARD

>15_

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Climbing hills improperly. WHAT CAN Improper hill climbing

could cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for climbing hills as described in the owner’s manual. See page 61.

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 43.

Switch the AWD switch out of TURF mode and into AWD mode when ascending a hill.

HAPPEN

THE

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Traveling downhill

improperly. WHAT CAN Improperly

descending a hill could cause loss of control or overturn.

HOW TO AVOID HAZARD

Always follow proper procedures for traveling down hills as described in the owner’s manual. See page 63.

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 43. 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.

HAPPEN

THE

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Improperly crossing hills and

turning on hills. WHAT CAN Improperly crossing or

turning as hills could cause loss of control or overturn.

HOW TO AVOID HAZARD

Neverattempttoturnthe ATV around on any hill until you’ve mastered the turning technique (on level ground) as described in the owner’s manual. See page 64. 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 Always follow proper procedures as described in the owner’s

manual. Avoid hills with excessively slippery or loose surfaces. Shift body weight uphill.

HAPPEN

THE

hill:

Rider Safety

WARNING

POTENTIAL HAZARD Stalling, rolling backwards

or improperly dismounting while climbing a hill.

WHAT CAN The vehicle could overturn. HOW TO AVOID

HAZARD

Maintain steady speed when climbing a hill.

If all forward speed is 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 64.

If the ATV begins rolling 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 64.

HAPPEN

THE

lost:

backwards:

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Improperly operating over obstacles. WHAT CAN Operating over obstacles could cause loss of control or overturn. HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Skidding or sliding. WHAT CAN Skidding or sliding can cause loss of control. If the tires regain traction unexpectedly, the ATV could overturn. HOW TO AVOID THE On slippery surfaces such as ice, travel slowly and use extra

caution to reduce the chance of skidding or sliding out of control.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Improperly operating in reverse. WHAT CAN The ATV could collide with an obstacle or person, resulting in

severe injury. HOW TO AVOID THE Before shifting into reverse gear, always check for obstacles or

people behind the ATV. When it’s safe to proceed, back slowly. Be aware that a passenger can obstruct your view.

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

POTENTIAL HAZARD Operating the ATV through deep or fast-flowing water. WHAT CAN Tires may float, causing loss of traction and loss of control, which

could lead to an accident or overturn. HOW TO AVOID THE 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 66), 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.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Operating this ATV with improper tires, or with improper or

uneven tire pressure. WHAT CAN 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 Always use the size and type of tires specified for the ATV. Always maintain proper tire pressure as specified.

HAPPEN

HAZARD

SAFETY

Rider Safety

WARNING

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

may cause changes in handling which could lead to an accident. HOW TO AVOID THE 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.

HAPPEN

HAZARD

WARNING

POTENTIAL HAZARD Overloading the ATV or carrying/towing cargo improperly. WHAT CAN Overloading and towing can cause changes in vehicle handling,

which could lead to loss of control or an accident. HOW TO AVOID THE Never exceed the stated load capacity for this ATV. Make sure cargo is 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 70. Always follow the instructions in the owner’s manual for operating

with a passenger. See page 58.

HAPPEN

HAZARD

SAFETY

Rider Safety

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.

WARNING

After any overturn or accident, have a qualified service dealer inspect the entire vehicle for possible damage, including (but not limited to) brakes, throttle and steering systems.

WARNING

Safe operation of this rider-active vehicle requires good judgement and physical skills. Persons with cognitive or physical disabilities who operate this vehicle or ride as a passenger 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.

CAUTION

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.

CONTROLS

Engine Electrical 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 (1) - 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 AWD in reverse,

if the AWD switch is on. This switch is also used to toggle through the different modes of the rider information center. See page 46.

Engine Stop Switch (2) - The engine will

OFFOFF

not start or run when the switch is in the

RUN

OFF position. Its purpose is to provide the operator with a quick means of engine shutdown in case of an emergency.

Main Switch (3) - To start the engine, slide

the stop switch to the center RUN position and turn the m ain key switch clockwise past the ON position. Release t he key when the engine starts.

NOTE: Both the main switch and the emergency engine stop switch

will shut off all electrical power to the vehicle, including lights. To stop the engine, slide the stop switch either right or left to the OFF position.

Worklight Switch (4) - The worklight switch controls a light located at the rear of the vehicle. Use the rear light when additional light is needed for loading and unloading the vehicle. Turn the rear worklight off when driving the ATV.

CONTROLS

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.

Throttle Lever

Engine speed and vehicle movement are controlled by pressing the throttle lever (1). 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

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle system malfunction and is provided for your safety. Do not attempt to modify the ETC system or replace it with any after market throttle mechanisms.

CONTROLS

Light Switches

The light switch is located on the left handlebar. It’s used to turn the lights on and off and to switch the lights from HI to LO.

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

and the shut-off 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.

Brake Lever

The front and rear brakes are applied by squeezing the brake lever (1) toward the handlebar. The front and rear 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.

Master Cylinder

The brake fluid in the master cylinder (1), which is located on the left handlebar, should be checked before each ride. The fluid level can be seen through an indicator window (2) on the top of the master cylinder. This eye will appear dark when the fluid level is full. When fluid needs to be added, the eye will be clear.

CONTROLS

NOTE: When checking the fluid level, the A TV must be on level

ground with the handlebars straight. If the fluid level is low add DOT 3 brake fluid only. See page 117 for the part numbers of Polaris products.

WARNING

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

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.

Setting the Parking Brake

1. Place the transmission in PARK.

2. Squeeze and release the brake lever (1) two or three times, then squeeze and hold.

3. Push the park brake lock (2) forward to engage the brake. Release the brake lever.

4. To release the parking brake lock, squeeze and release the brake lever. It will return to its unlocked position.

Important Safeguards

S The parking brake may relax if left on for a l ong period of time. Al-

ways block the wheels to prevent rolling.

S Always block the wheels on the downhill side of the ATV if leaving

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

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

hill. Always block the wheels to prevent rolling.

CONTROLS

Auxiliary Brake

WARNING

Aggressively applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.

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.

Your Polaris ATV has an auxiliary brake for added safety. It’s located on the inside of the right floor board and is operated by the right foot. The auxiliary brake serves as a backup to the main brake system if the main system becomes inoperative.

If the rear wheels slide while using t he auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.

Brake Fluid Level

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

CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector (1) is located on the right side of the vehicle.

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

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.

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

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 T ank

The fuel tank filler cap (1) is located directly below the handlebar. Use either leaded or unleaded gasoline with a minimum pump octane number of 87=(R+ M/2) octane.

Fuel Filter

The in-line fuel filter should be replaced by your dealer 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.

FEATURES

All Wheel Drive (AWD) System

The AWD system is activated by a switch (1) on the right handlebar.

When the switch is on 2X4 (center position), the ATV i s in two wheel drive at all times and the differential is locked.

When the switch is on A WD (left position), the ATV is in AWD and the differential is locked. When in AWD, the front gearcase will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the front gearcase 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 switch is on. See page 36.

When the switch is on TUR F (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.

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

All Wheel Drive (AWD) System

Engaging F ront Gearcase

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 front gearcase 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.

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 return 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 (A) is securely latched.

2. Lift the latch (B) at the top of the operator backrest and tilt the backrest slightly forward.

3. Pull the passenger seat backrest (C) upward from the bed of the cargo box.

FEATURES

Passenger Seat

4. Continue lifting the backrest latch while lowering the backrest to create the passenger seat (D).

5. Release the backrest latch and make sure the under-seat latch is fully engaged. If the seat can be lifted, repeat the procedure until the under-seat latch engages.

6. Lift the adjustment latch (E) 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 t hree operating positions.

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

before it can be 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.

7. Test the passenger seat lock-out by attempting to release the cargo box dump lever (A). If the dump lever releases, the seat is not secure. Repeat the set-up procedure.

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

passenger to ride the vehicle. See your Polaris dealer for service.

8. To return the vehicle to 1-up operation, reverse all steps. Be sure to lower the passenger backrest to the lowest position before folding it down into the cargo box. Make sure both backrests lock securely in place.

FEATURES

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from the right front wheel. The instrument cluster measures distance in miles or kilometers 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 36 for additional information.

1. Rider Information Center

2. Speedometer needle - in addition to showing vehicle speed, the needle flashes when a warning condition exists.

3. Speedometer

CAUTION

To prevent damage, wash the ATV by hand or with a garden hose using mild soap. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster. Do not allow insect sprays to come into contact with the lens.

FEATURES

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 have occurred and the instrument cluster may have shut off to protect the cluster’s electrical system. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

1. Gear Indicator - As the shift lever is moved, this indicates the gear the transmission is in:

H = High Range

L = Low Range N = Neutral R = Reverse P=Park

2. AWD Indicator - This indicator illuminates when the electrical portion of the AWD system is enabled.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery or Over Voltage - This warning usually indicates that the ATV is being operated at an RPM too low to keep the battery charged. A low battery warning may also occur under normal operation if the machine is at idle and high electrical load (lights, cooling fan, accessories) is applied. Driving at a higher RPM or connecting a battery charger will usually clear the warning.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

7. Fuel Gauge - The segments of the fuel gauge show the level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments will flash, “FUEL” will display in the LCD, and the speedometer needle will blink. Refuel immediately.

8. Check Engine Warning Indicator - This indicator serves two purposes. The word HOT displays if the engine overheats. It also appears if an EFI-related fault occurs. Do not operate the A TV if this warning appears. Serious engine damage could result.

9. Mode Indicator

FEATURES

Instrument Cluster

Rider Information Center

The rider information center has 4 standard modes: Mode 1 - Odometer Mode 2 - Tripmeter Mode 3 - Total Service Hours Mode 4 - Tachometer The reverse override button on the left handlebar is also the mode

button.

NOTE: If using the mode button to program the rider information

center, or to toggle through the options, the machine cannot be in reverse.

Mode 1 - Odometer

The odometer records the miles traveled by the ATV.

Mode 2 -Trip Meter

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

Mode 3 - Hour Meter

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

Mode 4 - Tachometer

The engine RPM is displayed digitally.

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

normal because of changes in humidity, temperature, elevation and electrical loads.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

The diagnostic mode is for informational purposes only. Please return your ATV to your dealer for all major repairs.

As long as the gauge is in the diagnostic mode, the wrench icon will remain lit.

To leave the diagnostic mode, turn the key switch off and on.

NOTE: Any movement of the tires will also take the machine out of

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.

5. Release the switch as soon as the display is activated.

The initial screen display refers to the software version installed in your ATV. This information is displayed briefly.

Use the mode/reverse override button to toggle through the diagnostic screens.

Screen 1: Battery voltage

Screen 2: Tachometer

Screen 3: AWD diagnostic

This gauge indicates whether or not current is flowing through the AWD coil (only on models with switchable AWD).

Screen 4: Gear circuit diagnostic This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Mode

Screen 5: Programmable service interval The purpose of the programmable service interval is to provide the

consumer and dealer with a convenient reminder for routine maintenance. When your vehicle leaves the factory, this feature is set at 50 hours. You m ust enable the programmable service interval before it can be used.

Once the service interval mode is set with the hours when service is due, the hours of actual engine operation are subtracted from the set hours until 0 is reached. When the counter reaches 0, the wrench icon will flash quickly for 5 seconds each time the vehicle is started as a reminder that the periodic maintenance is due.

To set the hours, press and hold the mode/override button until the wrench icon flashes. When it begins to flash, release the button. The setting will increase by one hour each time the button is pressed. Pressing and holding the button will allow the numbers to escalate much faster. When the desired time increment is displayed, release the button and wait for the wrench to stop flashing. When the wrench stops blinking, your service hours are set.

NOTE: If you scroll past the intended number, hold the button down

If the service interval is enabled on your ATV and you wish to turn it off, toggle to the service interval mode. Press and hold the mode button for approximately 7 seconds until the word OFF appears in the Rider Information Center.

Screen 6: Miles/Kilometers toggle The display in the tripmeter and odometer can be changed to display

either kilometers or miles. The current display mode will be shown as KM or MP. To change, hold in the mode button until the letters flash, then press and release the button once. When the display stops flashing, the mode has been set.

until the count turns over to 0. You can then reset the number.

FEATURES

Instrument Cluster

Rider Information Center

Special EFI Diagnostic Mode

The EFI diagnostic mode is for informational purposes only. Please see your Polaris dealer for all major repairs. To download blink codes (failure codes) from the EFI module:

1. Place the transmission in PARK. Turn the engine off and turn the key switch to the ON position.

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

Blink Code

- No RPM Signal

21 Loss of Synchronization 54 Engine Temp Lamp: Short Circuit

45 Barometric Pressure Sensor:

46 Barometric Pressure Sensor:

22 TPS: Open or Short Circuit to

22 TPS: Short Circuit to Battery 55 Diag Lamp: Short Circuit to

23 RAM Error: Defective ECU 56 Pump Relay: Open Load

42 Engine Temp Sensor Circuit:

51 Injector 1: Open Load 41 Intake Air Temp Sensor: Open or

51 Injector 1: Short Circuit to Ground 41 Intake Air Temp Sensor: Short

51 Injector 1: Short Circuit to Battery 61 END

52 Injector 2: Open Load

52 Injector 2: Short Circuit to Ground

52 Injector 2: Short Circuit to Battery

Failure Description Blink

Circuit Low Input

Circuit High Input

Ground

Short to Ground

Open or Short to Battery

Code

54 Engine Temp Lamp: Open Load

54 Engine Temp Lamp: Short Circuit

55 Diag Lamp: Open Load

55 Diag Lamp: Short Circuit to

56 Pump Relay: Short Circuit to

Failure Description

to Ground

to Battery

Ground

Battery

Ground

Battery

Short Circuit to +Sensor Voltage

Circuit to Ground

OPERATION

Fuel Safety

WARNING

Gasoline is highly flammable and explosive under certain conditions.

S Always exercise extreme caution whenever handling gasoline. S Always refuel with the engine stopped, and outdoors or in a well

ventilated area.

S Never fill a gas container while it’s in the cargo box. Static elec-

tricity between the box and container could cause a spark.

S Do not smoke or allow open flames or sparks in or near the

area where refueling is performed or where gasoline is stored.

S Do not overfill the tank. Do not fill the tank neck. S If gasoline spills on your skin or clothing, immediately wash it off

with soap and water and change clothing.

S 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 42.

2. Check the oil reservoir level on the dipstick. See page 81. 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 54.

6. Pull only light loads.

7. During the break-in period, change both the oil and the filter at 20 hours, 200 miles, or one month, whichever comes first.

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 Inspection

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.

Pre-Ride Checklist

Item Remarks See

Page

Passenger seat lock-out Ensure proper operation 44

Brake system / lever travel Ensure proper operation 38, 90

Brake fluid Ensure proper level 39

Auxiliary brake Ensure proper operation 41

Front suspension Inspect, lubricate if necessary 79

Rear suspension Inspect, lubricate if necessary 79

Steering Ensure free operation --

Tires Inspect condition and pressure 94

Wheels / fasteners Inspect, ensure fastener tightness 95

Frame nuts, bolts, fasteners Inspect, ensure tightness --

Fuel and oil Ensure proper levels 81

Coolant level (if applicable) Ensure proper level --

Coolant hoses (if applicable) Inspect for leaks --

Throttle Ensure proper operation 37,116

Indicator lights / switches Ensure operation 38

Engine stop switch Ensure proper operation 36

Air filter, pre-filter Inspect, clean 96

Air box sediment tube Drain deposits whenever visible --

Headlamp Check operation, apply Polaris dielec-

tric grease when lamp is replaced

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

tric grease when lamp is replaced

Riding gear Wear helmet, goggles, protective

clothing

100

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.

4. Sit on the vehicle and turn 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. Activate the starter for a maximum of five seconds, releasing the key when the vehicle starts. If the engine does not start, return the keytotheOFF position and wait five seconds before attempting t o 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 contaminants such as water or excess fuel in t he bottom of the oil tank. Water in the bottom of the tank can lead to engine damage and must be drained. Water accumulation increases as outside temperature decreases.

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

OPERATION

Driving Procedures

1. Wear appropriate riding gear. See page 13.

2. Perform the pre-ride inspection. See page 54.

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, then shift the transmission into gear.

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

9. Shift the transmission into gear.

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

Making Turns

Both rear wheels drive equally at all times, except when operating i n 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, allowing the turn to be made smoothly.

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

NOTE: Practice making turns at slow speeds before attempting to

turn at 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 13.

3. Perform the pre-ride inspection. See page 54.

4. Convert the seat for 2-up riding. See page 44. 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. Control 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 62.

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 t he 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 s hift 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 l evel 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

Driving Uphill

<15_

Whenever traveling uphill, follow these precautions:

1. Always travel straight uphill.

2. Avoid steep hills (15_ maximum).

3. Keep both feet on the footrests.

4. Shift body weight uphill.

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

6. Remain alert and be prepared to take emergency action. This may include quick dismounting of the vehicle.

7. 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

64.

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 Hillside

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 the most dangerous type of driving encountered and should be avoided if at all possible. If you do enter into 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 t he 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

Driving Downhill

<15_

Whenever descending a hill, follow these precautions:

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

2. Slow down.

3. Proceed directly downhill.

4. Shift body weight uphill.

5. Apply the brakes slightly toaidinslowing.

Familiarize yourself with operation of the auxiliary brake in the event loss of normal service brakes occurs.

WARNING

Excessive speed can cause loss of control and lead to serious injury or death. Always operate slowly when traveling downhill.

OPERATION

Turning Around on a Hill

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

8’ (2.4 m)

OPERATION

Turning Around on a Hill

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

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

3. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill.

NOTE: If a passenger is on board, ask the passenger to dismount

first, then the operator may dismount.

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

5. While holding the service brake, 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.

6. Lock the parking brake and remount the vehicle from the uphill side, keeping body weight uphill.

7. Restart the engine with the transmission still in forward.

8. Release the parking brake and proceed slowly, controlling speed with the service brake, until the vehicle is on more level ground.

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

firm, level ground.

OPERATION

Driving Through Water

Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests (1). 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 if possible.

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

After running the vehicle in water, it’s critical to have it serviced as outlined in the maintenance chart. See page 74. The following areas need special attention: engine oil, transmission oil, front gearcase, and all grease fittings.

OPERATION

Driving Through Water

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 102. Have the vehicle serviced by your dealer at the first opportunity.

OPERATION

Driving in Reverse

Follow these precautions when operatinginreverse:

1. Always avoid backing downhill.

2. Always check for obstacles or people behind the ATV before operating in reverse. Be aware that a passenger can obstruct your view.

3. When it’s safe to proceed in reverse, move slowly and avoid turning at sharp angles.

4. When in reverse, apply the brakes lightly for stopping.

5. Never open the throttle suddenly while backing.

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.

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

The override button should be used with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Open the throttle just enough to maintain a desired speed.

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.

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.

ParkingonanIncline

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

1. Turn the engine off.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Always block the rear wheels on the downhill side as shown in the illustration.

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:

S Never exceed the stated load capacity for this vehicle. S Never carry cargo in the rear box when operating the ATV in the

2-up mode with a passenger.

S Reduce speed and allow a greater distance for braking. S When operating over rough or hilly terrain, reduce speed and

cargo to maintain stable driving conditions.

S WEIGHT DISTRIBUTION in the cargo bed should be as far for-

ward 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 offcentered loads that cannot be centered, secure the load and operate with extra caution.

S ALL LOADS MUST BE SECURED 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.

S EXTREME CAUTION MUST BE USED when operating with

loads extending beyond the rack or cargo bed. Stability and maneuverability may be adversely affected, causing the machinetooverturn.

S Carrying a load on only the front rack or cargo bed may cause

an imbalanced condition and increases the possibility of vehicle overturn. Balance loads proportionally between the front rack and cargo bed, but do not exceed the stated load capacity.

S Use extreme caution when applying brakes with a loaded ve-

hicle. Avoid terrain or situations that may require backing downhill.

S Always attach the tow load to the hitch point. S 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.

S Do not obstruct the headlight when loading the front rack.

OPERATION

Hauling Cargo

Load Distribution

Your ATV has been designed to carry or tow a certain amount of load. Always read and understand the load distribution warnings listed on the warning labels, and never exceed the specified weights.

Cargo weight should be mounted as low as possible. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions.

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

2. Always operate the vehicle with extreme caution whenever 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.

Maximum Towing Capacities

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

Sportsman X2

500 EFI

Towing Load

(Level Ground)

1225 lbs. ( 556 kg) 120 lbs. (54.4 kg)

Vertical Hitch

Weight

Belt Life

Use low forward gear when hauling or towing heavy cargo to extend belt life.

OPERATION

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 (A) 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.

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 stator housing.

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 130.

NOTE: Service and adjustments are critical. If you’re not familiar

with safe service and adjustment procedures, have a qualified dealer perform these operations.

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

Severe Use Definition

S Frequent immersion in mud, water or sand S Racing or race-style high RPM use S Prolonged low speed, heavy load operation S Extended idle S Short trip cold weather operation

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

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

" Perform these procedures more frequently for vehicles subjected to

severe use.

E Emission-related service (Failure to conduct this maintenance will

not void t he emissions warranty but may affect emissions.)

J Have an authorized Polaris dealer perform these services.

WARNING

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

MAINTENANCE

onpage5

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Steering -- Pre-Ride --

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 --

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

-- Pre-Ride --

Air box sediment

tube

Coolant -- Daily -- Check level daily, change

Headlamp/tail lamp/worklight

Air filter,

main element

Recoil housing -- Weekly -- Drain water as needed,

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

" J

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

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

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

Engine breather

filter (if equipped)

-- Daily -- Drain deposits when visible

-- Daily -- Check operation; apply

-- Weekly -- Inspect; replace as needed

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

(Km)

Make adjustments as needed. See Pre-Ride Checklist on page 54.

as needed

coolant every 2 years

dielectric grease if replacing

check often if operating in wet conditions

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

General

lubrication

Throttle Cable/

ETC Switch

Throttle Body In-

take Duct

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

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

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

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

Oil tank vent hose

(if equipped)

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

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

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

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

100 H 12 M 1000 (1600) Inspect routing, condition

(Km)

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

change at one month

Remarks

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

Radiator

(if applicable)

Cooling hoses

(if applicable)

Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/ pipe

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

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

lines, filter, pump; replace lines every two years

surfaces

Ignition Timing 100 H 12 M 1000 (1600) Inspect

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

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

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

E Emission-Related Service

J Have an authorized Polaris dealer perform these services.

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

(whichever comes first)

Hours Calendar Miles

Clutches (drive

and driven)

Front wheel

bearings

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

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

Idle speed -- Adjust as needed

Toe adjustment -- Inspect periodically; adjust

Headlight aim -- Adjust as needed

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

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

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

(Km)

parts

when parts are replaced

Remarks

E Emission-Related Service

J Have an authorized Polaris dealer perform these services.

MAINTENANCE

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. Items not listed in the chart should be lubricated at the General Lubrication interval.

Lubrication Guide Key

" More often under severe use

L Polaris Premium All Season Grease or grease conforming to NLGI

No. 2, such as Conoco Superlube M or Mobilegrease Special

F Use Polaris Premium U-Joint Lube every 500 miles, before long

periods of storage, or after pressure washing or submerging.

Item Lube Method

Engine Oil Polaris Premium 4 Synthetic

Brake Fluid DOT 3 Only See page 39.

Transmission Oil Polaris Premium AGL Synthetic

Front Demand Drive Unit (Front Gearcase)

Front Prop Shaft Yok e ( A )

Ball Joint (B)

Rear Bearing Carrier (C)

0W40

Gearcase Lube

Premium Demand Drive Hub Fluid

FGrease Grease fittings (3 pumps

"LGrease

See page 81.

See page 85.

See page 87.

maximum).

Locate fitting and grease with grease gun.

MAINTENANCE

Premium 4 Synthetic Lubricant

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.

NOTE: See page 117 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 m ore 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.

MAINTENANCE

Oil Level

The oil dipstick and fill tube (1) are located on 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 and let it idle for 20-30 seconds. Stop the engine.

3. Remove the dipstick and 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 normal or safe range (2). Do not overfill.

ADD 8 OZ. NORMAL FULL

6. Reinstall the dipstick securely.

MAINTENANCE

Oil and Filter Change

Change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 74.

1. Position the vehicle on a level surface.

2. Clean the area around the drain plug at the bottom of the oil tank and the bottom of the engine.

3. Run the engine for two to three minutes, then turn it off.

4. Place a drain pan beneath t he oil tank and remove the drain plug (1). Allow the oil to drain completely.

5. Install a new sealing washer (2) on the oil drain plug.

NOTE: The sealing surfaces on the drain plug and the oil tank

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

6. Reinstall the drain plug. Torque to 14-17 ft. lbs. (19-23 Nm).

7. Disconnect the lower oil delivery hose and remove the screen fitting (3) from the oil tank. Clean the fitting.

NOTE: The fitting threads

must be sealed with LOCTITE PST 505 or PTFE seal tape.

8. Reinstall the screen fitting and rotate the fitting clockwise a minimum of 2 1/2 turns into the tank threads. Continue to rotate the fitting until the nipple of the fitting aligns with the mark (4) on the tank.

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

25 ft. lbs. (34 Nm).

9. Reattach the oil line.

MAINTENANCE

Oil Change

10. Place shop towels beneath t he oil filter. Using an oil filter wrench, turn the filter (1) counterclockwise and remove.

11. Lubricate the gasket on the new filter with a film of new engine oil. Check to make sure the gasket is in good condition. Also make sure the gasket from the old filter is not still on the engine.

12. Install the new filter and tighten by hand 1/2 to 3/4 turn after gasket contacts the engine.

13. 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: Thesealingsurfaceson

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

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

15. Remove the dipstick (2) and add two quarts (1.9 l) of the recommended oil. Reinstall the dipstick.

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

initially.

16. Place the transmission in neutral.

17. Lock the parking brake.

18. Prime the oil pump using the procedure on page 84. Then stop the engine and inspect for leaks.

19. Recheck the oil level on t he dipstick and add oil as necessary to bring it to the recommended level on the dipstick.

20. Dispose of used filter and oil properly.

MAINTENANCE

Oil Change

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 (1) approximately 2I from the oil tank (2), between the end of the oil tank vent fitting and the vent line’s pressure relief slit (3).

2. Run the engine 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 i s properly primed and ready for operation. If you do not hear

air, the line has not bled, and you’ll need to repeat the priming procedure.

MAINTENANCE

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 74. We recommend the use of Polaris P remium AGL Synthetic Gearcase Lubricant. See page 117 for the part numbers of Polaris products.

Oil Check

The transmission fill plug (1) is located on the left side of the ATV, under the rear fender, behind the wheel.

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Add the recommended oil as needed to bring the level to the bottom of the fill plug hole threads.

4. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm).

MAINTENANCE

Transmission Oil

Oil Change

The transmission drain plug (2) is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well.

1. Remove the fill plug. Remove the drain plug.

2. Drain the oil into a drain pan. Dispose of used oil properly.

3. Clean and reinstall the drain plug. Torque to 20-25 ft. lbs. (27-34 Nm).

4. Add 32 oz. (948 ml) of the recommended transmission oil to bring the level to the bottom of the fill plug.

5. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm).

6. Check for leaks.

MAINTENANCE

Front Gearcase Oil

Always check and change the front gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 66. Maintain the oil level even with the bottom of the fill hole threads (1). We recommend the use of Polaris Premium Demand Drive Hub Fluid. Use of other oils may result in improper operation of components. See page 117 for the part numbers of Polaris products.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the fill plug (2). View the oil level.

3. Add the recommended gearcase oil as needed to bring the level to the bottom of the fill hole threads.

4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

Oil Change

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Place a drain pan beneath the gearcase. Remove the gearcase drain plug (3) located on the bottom right-hand side.

4. Drain the oil. Dispose of used oil properly.

5. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).

6. Add 6 ounces (175 ml) of Polaris

7. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).

8. Check for leaks.

Premium Demand Drive Hub Fluid.

MAINTENANCE

Engine Cooling System

Radiator Coolant Level

To ensure that the coolant maintains its ability to protect the engine, we recommend that the system be completely drained every two years and a fresh mixture of antifreeze and water added. Polaris recommends the use of Polaris Premium 60/40 anti-freeze/coolant or a 50/50 mixture of high quality aluminum compatible anti-freeze/coolant and distilled water. Polaris Premium 60/40 is already premixed and ready to use. Do not dilute with water. See page 117 for the part numbers of Polaris products.

NOTE: Always follow the manufacturer’s mixing recommendations

for the freeze protection required in your area.

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

WARNING

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

1. To access the radiator pressure cap, open the front box lid and pull open the access door.

2. Remove the pressure cap (1).

3. Using a funnel, slowly add coolant through the radiator filler neck.

4. Reinstall the pressure cap, secure the access door and close the box.

NOTE: Use of a non-standard pressure cap will not allow the

recovery system to function properly. Contact your dealer for the correct replacement part.

MAINTENANCE

Engine Cooling System

Coolant Level

The recovery bottle (1) is located on the left side of the machine. To access the recovery bottle, remove the left side panel as outlined on page 93.

Maintain the coolant level between the minimum and maximum marks on the bottle (when the fluid is cool). Add coolant as needed.

Cooling System Operation

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

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

NOTE: Some coolant level drop on new machines is normal, as the

system is purging itself of trapped air. Observe coolant levels and maintain as recommended by adding coolant to the recovery bottle.

MAINTENANCE

Brakes

The front and rear brakes are hydraulic disc brakes, activated by moving the single brake lever toward the handlebar. These brakes are self-adjusting.

The following checks are recommended to keep the brake system in good operating condition. Check more often if brakes are used heavily under normal operation.

WARNING

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.

1. Always keep brake fluid at an adequate level (see page 39).

WARNING

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.

NOTE: Under normal operation, the diaphragm extends into the

reservoir as fluid level drops. If the fluid level is low and the diaphragm is not extended, a leak is likely and the diaphragm should be replaced. Always fill the reservoir as needed whenever the cover is loosened or removed to ensure proper diaphragm operation. Use Polaris DOT 3 brake fluid. Do not overfill.

Brakes

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or spongy feel.

4. Check the friction pads for wear, damage and looseness.

5. Check the security and surface condition of the disc.

MAINTENANCE

NOTE: Pads should be changed

when worn to 3/64″ (.1 cm).

3/64″ (.1 cm)

Auxiliary Brake

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, the rear brake can be activated by depressing the foot pedal on the inside of the right footrest. The hydraulic auxiliary brake system requires no adjustment.

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

the all-wheel single lever system.

MAINTENANCE

Steering Assembly

The steering assembly of the ATV should be checked periodically for loose nuts and bolts. If loose nuts and bolts are found, see your Polaris dealer for service before operating the vehicle.

Toe Alignment

WARNING

Severe injury or death can result from improper toe alignment and adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments should be performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of t he vehicle. The recommended toe alignment is 1/8″ to 1/4″ toe out.

1. Set the handlebars in a straight-ahead position.

NOTE: Thesteeringfrogcan

be used as an indicator of whether the handlebars are straight. The frog should always point straight back from the steering post.

2. Place stands (1) in front of the vehicle, perpendicular to the rear tires. See illustration.

3. Tie an elastic string around the stands, making sure the string just touches the side surface of the rear tires on each side of the vehicle and goes around the stands in

front of the vehicle (2).

4. Measure the distance from the string to the rim at the front and rear of the front rim (3). Rear measurement should be 1/16″ -1/8″ (.2 to .3 cm) more than the front measurement.

NOTE: If you discover improper alignment, see your Polaris dealer

for service.

MAINTENANCE

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm motion, pull the panel outward to disengage the side panel from the grommet.

3. Pull the panel downward and rearward to remove it from the ATV.

4. Reinstall the side panel by reversing the removal procedure.

Footwell Removal

1. Remove the six screws (1) on the bottom of the footwell.

2. Use a flat screwdriver or sidecutters to remove the four plastic rivets (2) securing the footwell to the fenders.

3. Remove the footwell.

MAINTENANCE

WARNING

Operating your ATV with worn tires, improperly inflated tires, non-standard tires or improperly installed tires will affect vehicle handling and could cause an accident resulting in serious injury or death.

Maintain proper tire pressure as described on the decal on your ATV and in the owner’s manual.

Always use original equipment size and type when replacing tires. Make sure the wheels are installed properly. Always replace tires when the tread depth measures 1/8″ (.3 cm)

or less.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8″ (.3 cm) or less. See illustration.

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical component operations. All service must be performed by your authorized Polaris dealer.

1/8I (.3 cm)

Wheel Removal

1. Stop the engine. Place the transmission in PARK.

2. Lock the parking brake.

3. Loosen the wheel nuts slightly.

4. Elevate the side of the vehicle by placing a suitable stand under the footrest frame.

5. Remove the wheel nuts and remove the wheel.

MAINTENANCE

Wheel Installation

WARNING

Improperly installed wheels can adversely affect tire wear and vehicle handling, which can result in serious injury or death. Always ensure that all nuts are torqued to specification. Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

1. Place the transmission in PARK. Lock the parking brake.

2. Place the wheel on the wheel hub with the valve stem toward the outside and the rotation arrows on the tire pointing toward forward rotation.

3. Install the wheel nuts and finger tighten.

4. Lower the vehicle to the ground.

5. Torque the wheel nuts to specification.

90 ft. lbs. (122 Nm)

Cast Aluminum Steel

27 ft. lbs. (37 Nm)

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they’ve been loosened for maintenance service.

Nut Type Nut Torque

1. Lug Nut 90 ft. lbs. (122 Nm)

2. 2-Piece Flange Nut 27 ft. lbs. (37 Nm)

MAINTENANCE

Filter Systems

Air Filter Service

1. Remove the seat, release the air box cover clips, and remove the air box cover.

2. Loosen the clamp and remove the filter.

3. Remove the fabric type pre-filter (1) from the main filter (2). Wash the pre-filter in soapy water, then rinse and let dry.

4. Reinstall the pre-filter over the main filter. (Replace the main filter if needed.)

5. Reinstall the filter into the air box and tighten the clamp. Do not over tighten the clamp, as filter damage could occur.

6. Reinstall the air box cover and the seat.

Breather Filter/Hose

1. To access the breather filter (3), remove the left side panel as outlined on page 93. The breather filter is on the hose that runs between the engine and air box.

2. Remove the clamps and pull the filter out of the hoses.

NOTE: It’s not necessary to remove the lower hose from the engine.

3. Inspect the filter for debris. Blow gently through the filter in the direction of the arrow to check for clogging. Replace if needed.

4. Check the hoses for cracks, deterioration, abrasion, or leaks. Replace as needed.

5. Reinstall the filter and secure the clamps.

NOTE: The filter is effective with the arrow pointing in either

direction.

CAUTION

Operation of your vehicle without a breather filter can cause engine damage. Always reinstall the breather filter after removing for service.

MAINTENANCE

Lights

When servicing a halogen lamp, don’t touch the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp.

WARNING

Poor lighting while driving can result in severe injury or death. Headlight and taillight lenses become dirty during normal operation. Wash the headlights frequently to maintain lighting quality.

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

Headlight Lamp Replacement

1. Remove the two screws on the lower front corners of the headlight pod.

2. Remove the screw from the rear of the pod.

3. Lift the pod slightly while depressing the tabs at the rear of the pod.

4. Lift the pod cover and disconnect the speedometer harnesses from the speedometer.

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

6. Turn the lamp counterclockwise to remove it.

7. Apply dielectric grease to the socket and install the new lamp.

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

housing.

8. Reassemble the pod.

Polaris Sportsmabn X2 500 EFI User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual