Polaris Sportsman 800 X2 User Manual

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WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

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

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

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

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

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

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

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

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

Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or in acc uracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2009 Sportsman 500/800 X2 Owner’s Manual P/N 9921845

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 28

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Emission Control Systems . . . . . . . . . . . . . . . 74

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 133

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 134

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

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

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

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

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

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

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

INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A Polaris ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly , even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.

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

• 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 (800) 887-2887 or visit www.atvsafety .org for information on enrollment in the ATV RiderCoursesm.

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

• 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.

. Contact A TV Enrollment Express at

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

500

800

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

SAFETY

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

RiderCourse

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

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

RiderCourse

by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be charged for this training.

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

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

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

3764.

available to you and your eligible family members. This

. You were also provided with

by calling A TV Enrollment Express at (800) 887-2887 or

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

051039

0006.31

Safe Riding Gear

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

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards. A passenger (on approved models) should wear a helmet that includes a rigid chin guard.

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

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

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Equipment Modifications

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.

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

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

WARNING

Safety Warnings

Failure to operate the ATV properly can result in a collision, loss of control, accident or overturn, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.

Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.

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.

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.

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.

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated area.

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

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

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

Exposure to Exhaust

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

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.

Failure to Inspect Before Operating

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

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

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

SAFETY

Safety Warnings

Protective Apparel

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

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

Carrying a Passenger

Do not carry a passenger until you have at least two hours of driving experience with this vehicle.

Carrying More Than One Passenger

Carrying more than one passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or overturn.

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

Using Alcohol or Drugs

Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.

Never consume alcohol or drugs before or while operating an ATV.

Safety Warnings

Carrying a Passenger in the Cargo Box

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. Never allow a passenger to ride in the cargo box.

Operating on Pavement

Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or overturn.

Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.

Operating on Public Roads

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

Never operate the ATV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.

SAFETY

Operating at Excessive Speeds

Operating the ATV at excessive speeds increases the operator's risk of losing control.

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

SAFETY

Safety Warnings

Physical Control of the ATV

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.

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.

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or overturn.

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

Practice turning at slow speeds before attempting to turn at faster speeds.

Never turn at excessive speed.

Jumps and Stunts

Attempting wheelies, jumps and other stunts increases the risk of an accident or overturn.

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

Safety Warnings

Improper Hill Climbing

Improper hill climbing could cause loss of control or overturn. Always follow proper procedures for climbing hills as described in the owner's manual. See page 61.

Never operate with the differential unlocked ( ) while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See pages 29 and

39.

Descending Hills Improperly

Improperly descending a hill could cause loss of control or overturn.

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

Never operate with the differential unlocked ( ) while operating on a hill or other irregular terrain. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See pages 29 and 39.

Crossing Hillsides

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

If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 62.

Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 64.

SAFETY

>15°

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly dismounting while climbing a hill could cause an overturn.

• Always maintain a steady speed when climbing a hill.

• Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39.

If all forward speed is lost:

• Lean forward to keep body weight uphill. A passenger should also lean uphill.

• Apply the single lever brakes.

• Lock the parking brake when fully stopped.

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

• Turn the ATV around and remount, following the procedure described in the owner's manual. See page 64.

If the ATV begins rolling backwards:

• Keep operator and passenger body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards.

• Apply the single-lever brake gradually.

• When fully stopped, apply th e 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.

Operating on Steep Hills

Operating on excessively steep hills could cause an overturn.

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

Safety Warnings

Operating on Slippery Terrain

Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or overturn.

Do not operate on excessively rough, slippery or loose terrain 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.

Operating in Unfamiliar Terrain

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

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

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

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 68.

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

SAFETY

Safety Warnings

Improper Tire Maintenance

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

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

Always maintain proper tire pressure as described in the owner's manual and on safety labels.

Operating Over Obstacles

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

Before operating in a new area, check for obstacles. Avoid operating over large obstacles such as rocks and fallen trees. If unavoidable, use extreme caution and always follow proper operating procedures as outlined in this manual. See page 67.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra caution to reduce the chance of skidding or sliding. Do not operate on excessively slippery surfaces.

SAFETY

Safety Warnings

Operating Through Deep Water

Operating the ATV through deep or fastflowing water could cause the tires to float, causing loss of control or overturn.

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.

• 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. After leaving water, test the brakes. Apply them lightly several times while driving. The friction will help dry out the pads.

Improper Cargo Loading

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

• Never exceed the stated load capacity for

this ATV.

• Cargo should be properly distributed and

securely attached.

• Reduce speed when carrying cargo or

pulling a trailer. Allow a greater distance for braking.

• Always follow the instructio ns in the owner's manual for carrying cargo or

pulling a trailer.

• Always follow the instructions in the owner's manual for operating with a

passenger. See page 58.

SAFETY

Safety Warnings

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice.

Never operate the ATV on a frozen body of water.

Poor Visibility

Operating the ATV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

SAFETY

Safety Warnings

Operating a Damaged ATV

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

Physical Skills

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

Hot Exhaust Systems

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

Unauthorized Use of the ATV

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

SAFETY

Age 16 Warning

General Warning

Discretionary Warning

Safety Labels and Locations

Warning labels hav e been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.

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

Age 16 Warning

WARNING

Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger.

NEVER operate this vehicle if you are under age 16.

7175375

SAFETY

Safety Labels and Locations

General Warning/Discretionary Warning

WARNING

Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR

DRIVER AND PASSENGER NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:

• without proper ATV training or instruction

• at speeds too fast for your skills or the conditions

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

• with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS:

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

in turns

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

• reduce speed and use extra caution at all times when carrying a passenger -

dismount passenger when conditions require

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

label LOCATE AND READ OPERATOR’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

WARNING

• Never operate this ATV on HILLS steeper than 15 degrees 15°. To

prevent overturn on hilly terrain, use throttle and brakes gradually.

• REVERSE operation can be dangerous even at low speeds. Steering

becomes difficult. To prevent loss of control, avoid sudden braking or sharp

turns.

7175377

SAFETY

Passenger Safety

Warning

Safety Labels and Locations

Passenger Safety Warning

WARNING

PASSENGER SAFETY T o reduce the risk of SEVERE INJUR Y or

DEAT H NEVER CARRY MORE THAN ONE

PASSENGER NEVER RIDE AFTER USING DRUGS

OR ALCOHOL NEVER carry a passenger too small to

firmly plant feet on footrests and securely grasp hand holds.

THE PASSENGER MUST ALWAYS:

• use an approved helmet and protective gear

• securely grasp hand holds and plant feet firmly on footrests while seated in the passenger seat

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

7175379

Safety Labels and Locations

Tire Pressure/Load

Warning

Tire Pressure/Load Warning

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa)

• Maximum weight capacity: 705 lbs.

(320 kg)

7175441

SAFETY

Clutch Cover

Warning

Rack

Warning

Box

Warning

Safety Labels and Locations

Rack Warning, Front

WARNING

DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum combined Front Rack and Container Load: 90 lbs. (41 kg)

7174201

Clutch Cover Warning

WARNING

NO STEP

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

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

7172563

SAFETY

Safety Labels and Locations

Reverse Override Warning/AWD Caution

WARNING

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

CAUTION

Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.

7175512

Box Warning

WARNING

Remove flammable material containers from box before filling.

WARNING

Passengers can be thrown off. This can cause serious injury or death. Never carry passengers in cargo box.

Maximum Box Load - 400 lbs. (181 kg)

7173890

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Worklight

Switch

(if equipped)

Main Key Switch

Engine

Stop Switch

Headlight

Switch

4X4

Switch

Differential

Switch

OFF OFFRUN

Switches

Mode/Reverse Override Switch

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

WARNING! Activati ng the override switch while the throttle is open can cause loss of control, which may result in serious injury or death. Always release the throttle before activating the override switch.

The override switch also allows activation of 4X4 in reverse, if the 4X4 switch is on. This switch is also used to toggle through the modes of the rider information center. See page 42.

Engine Stop Switch

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

Both the main switch and the engine stop switch will shut off all electrical power to the vehicle, including lights.

Main Key Switch

Use the main key switch to start the engine. See page 55.

4X4 Switch

Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 39.

FEATURES AND CONTROLS

Switches

Differential Switch

Use the differential switch to lock and unlock the rear differential.

Locked Differential: Operate the vehicle with the switch in the locked position in most conditions.

Unlocked Differential: When the differential is unlocked, the inside wheel will rotate independently from the outside wheel during turns. Operate with an unlocked differential only as needed to protect smooth, level surfaces from tire damage. Otherwise, move the switch to the locked position. This feature will function only if the vehicle is in 2X4 mode.

WARNING! Operating with the differential unlocked ( ) 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 with the differential unlocked ( ) when climbing or descending hills, when sidehilling, or when operating on uneven, loose, or slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings. Place the differential switch in the locked position and operate in ADC 4X4 or 4X4 on these types of terrain.

Worklight Switch

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

Headlight Switch

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

FEATURES AND CONTROLS

WARNING

Throttle Lever

Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.

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.

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

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

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

FEATURES AND CONTROLS

WARNING

Brake Lever

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. Always contact your dealer for service before operating the vehicle.

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

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

FEATURES AND CONTROLS

WARNING

Master Cylinder

Indicator

Window

Master Cylinder/Brake Fluid

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

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

Check the brake fluid in the master cylinder before each ride.

1. Position the ATV on a level

surface.

2. Position the handlebars so the

master cylinder is level.

3. View the brake fluid level

through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low , the eye will be clear.

4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

PARK.

2. Squeeze and release the brake

lever two or three times, then squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

5. To release the parking brake lock, squeeze and release the brake

lever. It will return to its unlocked position.

WARNING! Operating the ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.

The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.

FEATURES AND CONTROLS

WARNING

Auxiliary Foot Brake

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

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

The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Since this is a rear brake only , it will not be as ef fective as the allwheel single lever system.

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

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

Brake Fluid Level

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

FEATURES AND CONTROLS

Gear

Selector

Automatic Transmission Gear Selector

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

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

To shift gears, brake to a complete stop. When the engine is idling, move the lever to the desired gear.

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

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.

moving could cause transmission damage.

FEATURES AND CONTROLS

Fuel

Ta n k

Cap

Fuel Filter (500 EFI)

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

Fuel Tank Cap

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

FEATURES AND CONTROLS

4X4

Switch

All Wheel Drive System

The All Wheel Drive system is controlled by the 4X4 switch.

ADC 4X4 Mode

When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 39.

4X4 Mode

When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator light in the instrument cluster will be on.

When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage. There is no limit to the length of time the vehicle may remain in 4X4.

Tip: The override switch allows activation of 4X4 in reverse if the 4X4 switch is

on. See page 28.

2X4 Mode

When the switch is on 2X4, the ATV is in two-wheel drive at all times.

FEATURES AND CONTROLS

All Wheel Drive System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned of f while the demand drive unit is moving, it will not disengage until the rear wheels regain traction.

Engage the 4X4 switch before getting into conditions where front wheel drive may be needed. If the rear wheels are spinning, release the throttle before switching to 4X4.

NOTICE: Switching to 4X4 or ADC 4X4 while the rear wheels are spinning may

cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

FEATURES AND CONTROLS

Active Descent Control (ADC) System

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

Engaging Active Descent Control

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

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

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

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

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

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

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

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

FEATURES AND CONTROLS

Dump Lever

Passenger

Backrest

Operator Backrest Latches

(view from front)

Locked

Unlocked

Passenger Seat

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

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

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

Seat Conversion

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

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

3. Tilt the backrest slightly forward.

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

FEATURES AND CONTROLS

Passenger

Backrest

Adjustment

Latch

Locked

Passenger Seat

Seat Conversion

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

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

Tip: 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.

6. Lower the operator

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

7. Test the passenger seat

lock-out by attempting to release the cargo box dump lever. If the dump lever releases, the seat is not secure. Repeat the set-up procedure. 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 th e vehicle to single-rider

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

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

Your ATV is equipped with an instrument cluster that senses vehicle speed from a sensor in the transmission. In addition to showing vehicle speed, the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles as well as hours of operation. It also includes a reverse speed limiter function that limits the ATV's speed to approximately 7-9 mph. Refer to page 28 for additional information.

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

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

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

FEATURES AND CONTROLS

345

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster . All segments will light up for 2.5 seconds at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your Polaris dealer for proper diagnosis.

1. Gear Indicator - This

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

2. 4X4 Indicator - This

indicator illuminates when the 4X4 switch is on either ADC 4X4 or 4X4.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

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

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

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

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

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

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

9. Mode Indicator

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse override button is also the MODE button. See page 28. The transmission cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the ATV.

Trip Meter Mode

The trip meter records the miles traveled by the ATV on each trip if it's reset before each trip. To reset the trip meter , select the trip meter mode. Press and hold the mode button (override button) until the total changes to 0. In the Rider Information Center, the trip meter display contains a decimal point, but the odometer displays without a decimal point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM from day to day may be normal because of changes in humidity, temperature and elevation.

Clock Mode

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

45.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

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

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

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

Release the button.

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

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

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

onds, until the minute display flashes.

6. Use the same procedure to reset the minutes.

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

8. Do not turn the key switch off until the display stops flashing or the

new setting will not be locked into the memory.

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the all wheel drive coil. This screen is for informational purposes only. Please see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. See page 47.

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

5. If you scroll past the intended number, press and hold the button

until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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

See page 49 for Blink Codes and Failure Descriptions. Use the following procedure to download blink codes (failure codes) from the EFI module.

1. Place the transmission in PARK. Stop

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

2. Turn the key switch off and on three

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

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

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

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

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

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

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

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

Code Definitions

Open Load:

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

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

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

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink Code

12 BEGIN SEQUENCE 22 Throttle Position Sensor Low 22 Throttle Position Sensor High 22 Throttle Position Sensor Out of Adjustment 25 Gear Sensor Signal 31 System Voltage Low 31 System Voltage High 36 Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 36 Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 37 Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground 37 Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery 41 Air Temp Sensor Low Voltage 41 Air Temp Sensor High Voltage 42 Engine Coolant Temp Low Voltage 42 Engine Coolant Temp High Voltage 44 Crank Position Sensor Circuit Fault 45 Barometric Pressure/Manifold Air Pressure Sensor Low 46 Barometric Pressure/Manifold Air Pressure Sensor High 47 IAC Stepper Motor: Open Load 47 IAC Stepper Motor: Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground 51 Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery 52 Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground 52 Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery 55 MIL Circuit: Open Load/Short-to-Ground 55 MIL Circuit: Shorted Load/Short-to-Battery 56 Fuel Pump: Open Load/Short-to-Ground 56 Fuel Pump: Shorted Load/Short-to-Battery 58 Fan Circuit: Open Load/Short-to-Ground 58 Fan Circuit: Shorted Load/Short-to-Battery 59 ADC: Open Load/Short-to-Ground 59 ADC: Shorted Load/Short-to-Battery 63 Starter Enable: Open Load/Short-to-Ground 63 Starter Enable: Shorted Load/Short-to-Battery 72 Gear Sensor Signal 73 4X4: Open Load/Short-to-Ground 73 4X4: Shorted Load/Short-to-Battery 74 Rear Differential Enable: Open Load/Short-to-Ground 74 Rear Differential Enable: Shorted Load/Short-to-Battery 61 END SEQUENCE

Failure Description

OPERATION

WARNING

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

Break-In Period

The break-in period for your new Polaris 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.

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

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

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 36. Always exercise

extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 80. 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 famil-

iarize 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 52.

6. Pull only light loads.

7. Change both the oil and the filter at 20 hours or one month, which-

ever 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 Checklist

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

Item Remarks Page

Passenger seat lock-out Ensure proper operation 40

Brake system/lever travel Ensure proper operation 31

Brake fluid Ensure proper level 32

Auxiliary brake Ensure proper operation 34

Front suspension Inspect, lubricate if necessary 79

Rear suspension Inspect, lubricate if necessary 79

Steering Ensure free operation -

Tires Inspect condition and pressure 97

Wheels/fasteners Inspect, ensure fastener tightness 97

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 36

Coolant level (if applicable) Ensure proper level 92

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 30

Indicator lights/switches Ensure operation 28

Engine stop switch Ensure proper operation 28

Air filter, pre-filter Inspect, clean 99

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

Brake light/taillight Check operation, apply Polaris dielec-

Riding gear Wear approved helmet, goggles, and

ADC Fluid Ensure proper level 90

tric grease when lamp is replaced

protective clothing

128

102

105

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

2. Do not allow anyone under 16 years of age to operate this vehicle.

Do not allow anyone with cognitive or physical disabilities to operate this vehicle.

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

run in an enclosed area.

4. Before operating, learn how to use the auxiliary brake for emer-

gency situations (if service brakes become inoperable).

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

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

6. Use caution and drive at reduced speeds in conditions of reduced

visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.

7. Drive in a manner appropriate for your skills, your passenger’s

skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.

8. Never consume alcohol or drugs before or while operating an ATV.

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

Always maintain proper tire pressure.

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

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

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

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

OPERATION

Know Your Riding Area/Tread Lightly

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

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

Trail Etiquette

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

OPERATION

Starting the Engine

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

lated area.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

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

Tip: 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 engine starts.

500 EFI ONLY: The starter will automatically stop if engaged for longer than 5 seconds. Move the key to the OFF position and wait 10 seconds before engaging the starter again.

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

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

NOTICE: Operating the vehicle immediately after starting could cause engine

Cold Weather Operation

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

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

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

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 52.

3. Place the transmission in PARK.

4. Lock the parking brake.

5. Mount the vehicle from the left side.

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

handlebars.

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

8. Shift the transmission into gear.

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

10. Release the parking brake.

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

12. Drive slowly. Practice maneuvering and using the throttle and

brakes on level surfaces.

OPERATION

Turning the Vehicle

Both rear wheels drive equally at all times (except when operating in 2X4 mode with the differential unlocked). 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.This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly. The same leaning technique should be used for turning in reverse.

6. Practice making turns at slow speeds before attempting to turn at

faster speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn abruptly or at sharp angles. Never turn at high speeds.

OPERATION

Driving with a Passenger

1. 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 grab handles and footrests.

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

experience with this vehicle.

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

ing an approved helmet with a rigid chin guard. See page 8.

4. Perform the pre-ride

inspection. See page 52.

5. Convert the seat for 2-up

riding. See page 40. Always make sure the passenger seat lock-out is functioning properly before carrying a passenger.

6. Lock the parking brake.

7. 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.

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

9. Never carry more than one passenger.

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

board. Allow more time and distance for braking.

OPERATION

Driving with a Passenger

11. Ride to the ability of your passenger, instead of to your own ability.

Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.

12. Do not cross a hillside with a passenger on board. See page 62.

13. 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. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.

14. Make sure the passenger understands the importance of "active

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

OPERATION

Sideways

skid

Tur n in

direction of

skid

Driving on Slippery Surfaces

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

1. Do not operate on excessively rough, slippery or loose terrain.

2. Slow down when entering slippery areas.

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

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

4. Maintain a high level of alertness, reading the trail and avoiding

5. Never apply the brakes during a skid. Correct a skid by turning the

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

quick, sharp turns, which can cause skids.

handlebars in the direction of the skid and shifting your body weight forward.

OPERATION

15° Maximum

Driving Uphill

Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or overturn. Whenever traveling uphill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

2. Never operate with the differential unlocked ( ) while operating

on a hill or other irregular terrain. See pages 29 and 39.

3. Drive straight uphill.

4. Avoid steep hills (15° maximum).

5. Always check the terrain carefully before ascending any hill.

6. Never climb hills with excessively slippery or loose surfaces.

7. Keep both feet on the footrests.

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

uphill.

9. Proceed at a steady rate of speed and throttle opening. Opening the

throttle suddenly could cause the ATV to flip over backwards.

10. 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.

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

include quick dismounting of the vehicle.

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. If operating in 2X4 mode, make sure the differential is locked.

4. Do not cross a hillside with a passenger on board. Ask the passenger

to dismount and walk across the hillside before remounting the vehicle.

5. Lean into the hill, transferring your upper body weight toward the

hill while keeping your feet on the footrests.

6. If the vehicle begins to tip, quickly turn the front wheel downhill, if

possible, or dismount on the uphill side immediately!

OPERATION

15° Maximum

Driving Downhill

When driving downhill, follow these precautions:

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

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

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

descend a hill with the transmission in neutral.

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

5. Drive straight downhill. Avoid traveling down a hill at an angle,

which would cause the vehicle to lean sharply to one side.

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

uphill.

7. Apply the brakes slightly to aid in slowing. Applying the brakes too

firmly may cause the rear wheels to lock, which could result in loss of control.

OPERATION

8 ft. (2.4 m)

Turning Around on a Hill (K-Turn)

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

OPERATION

Turning Around on a Hill (K-Turn)

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

2. Always move the 4X4 switch to ADC 4X4 before ascending or

descending a hill. See page 39.

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

4. If a passenger is on board, ask the passenger to dismount first, then

the operator may dismount. Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. A passen-

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

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

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

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

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

keeping body weight uphill.

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

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

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

OPERATION

Maximum Depth

Driving Through Water

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

1. Determine water depths

and current before entering water.

2. Choose a crossing where

both banks have gradual inclines.

3. Avoid operating through deep or fast-flowing water.

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

4. After leaving water, test the brakes. Apply them lightly several

If it’s unav oidable to enter water deeper than the footrest level:

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

• Maintain a steady rate of speed. Do not make sudden turns or stops. Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in the maintenance chart. See page 75. The following areas need special attention: engine oil, transmission oil, demand drive fluid and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during or after operating in water, restarting can result in serious engine damage. Transport the vehicle to your dealer for service before restarting the engine. If this is not possible, follow the vehicle immersion inspection and drying procedures outlined on page 108, then see your dealer for service at the first opportunity.

times while driving slowly. The friction will help dry out the pads.

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

2. Look ahead and learn to read the terrain. Be constantly alert for haz-

ards such as logs, rocks and low hanging branches.

3. Travel slowly and use extra caution when operating on unfamiliar

terrain. Not all obstacles are immediately visible.

4. Never attempt to operate over large obstacles, such as rocks or

fallen trees.

5. Always have a passenger dismount before operating over an obsta-

cle that could cause a fall from the vehicle or vehicle tipover.

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

that a passenger can obstruct your view.

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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

required for vehicle movement. Use the override with caution as rearward vehicle speed is greatly increased. Do not operate at wide open throttle. Operate the throttle just enough to maintain a desired speed.

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

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

OPERATION

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

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

OPERATION

WARNING

Hauling Cargo

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

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

REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.

NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the loa d on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity .

REDUCE SPEED AND CARGO to maintain stable driving conditions when operating over rough or hilly terrain.

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

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

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

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

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

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

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

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

OPERATION

Hauling Cargo

Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of

this manual. Cargo weight should be

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

1. Always load the cargo

box with the load as far forward as possible.

2. Do not obstruct the headlight beam with cargo.

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

extend belt life.

4. Always operate the vehicle with extreme caution whenever hauling

or towing loads. Balance, handling, and control may be affected.

5. Slow down.

6. Make sure the cargo box dump latch is securely latched before load-

ing and operating. Unintentional dumping will result if weight is placed in the rear of the box and the latch is not secured.

OPERATION

Maximum

4" (10 cm)

Hauling Cargo

Towing Loads

Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.

• The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.

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

NOTICE: Using an improper hitch or

Maximum Towing Capacities

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

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

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

exceeding the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your Polaris ATV. Always install Polaris-approved (or equivalent) accessories designed for ATV use.

500 EFI 800 EFI

OPERATION

Dump Box

Release

Latch

Hauling Cargo

Dumping Cargo

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

unload the vehicle while parked on an incline.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Dismount the vehicle.

5. Lower the tailgate.

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

6. Pull the cargo box release lever

upward.

7. Lift the front of the cargo box and

dump the cargo.

8. Lower the cargo box and make

sure the release latch is secured.

9. Secure the tailgate.

WARNING! Operating with the cargo box in the raised position can cause serious injury and damage to the vehicle. The cargo box could close unexpectedly and injure the driver. The rear tires will also catch the rear of the bed, damaging the vehicle and creating hazardous driving conditions. Never operate this vehicle with the cargo box in the raised position.

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 8343.1(c). 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 battery box.

Electromagnetic Interference

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

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

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 144.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

• Short trip cold weather operation Pay special attention to the oil level. A rise in oil level during cold

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

MAINTENANCE

WARNING

Periodic Maintenance Chart

Improperly performing the procedures marked with a Q could result in component failure and cause an accident, which may result in serious injury or death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

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

E Emission-related service

(Failure to conduct this maintenance will not void the emissions warranty but may affect emissions.)

Q Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Steering - Pre-Ride - Make adjustments as

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Passenger seat lock-out

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

Engine oil level - Pre-Ride -

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

X Air box sediment

tube

Coolant (if applicable)

X ADC fluid

(ADC models)

Headlight/taillight/ worklight

(whichever comes first)

Hours Calendar Miles

-Pre-Ride -

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check level daily, add as

- Daily - Check operation; apply

(Km)

needed. See Pre-Ride Checklist on page 52.

as needed

coolant every 2 years

needed

dielectric grease if replacing lamps

Remarks

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

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

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

X Rear gearcase oil

(if equipped)

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

filter (if equipped)

X General

lubrication

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

Steering 50 H 6 M 500 (800) Lubricate

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

Throttle Cable/

ETC Switch

E Throttle Body

Intake Duct

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

Cooling system (if applicable)

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

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

(whichever comes first)

Hours Calendar Miles

- Weekly - Inspect; replace as needed

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

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

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

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

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

50 H 6 M 1000 (1600) Inspect coolant strength

(Km)

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test system yearly

at one month

Remarks

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

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

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

X Radiator

(if applicable)

X Cooling hoses

(if applicable)

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

Exhaust muffler/ pipe

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

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

Clutches (drive and driven)

Front wheel bearings

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

ADC fluid (ADC models)

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

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

Toe adjustment - Inspect periodically; adjust

Headlight aim - Adjust as needed

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

Q Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

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

100 H 12 M 1000 (1600) Inspect for leaks

100 H 12 M 1000 (1600) Inspect

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

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

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

(Km)

lines, filter, pump; replace lines every two years

surfaces

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

parts

Replace every 2 years, more often under extreme conditions.

when parts are replaced

Remarks

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Items not listed in the chart should be lubricated at the General Lubrication interval.

The a-arms and upper control arms are lubricated at the factory, and no additional lubrication will be needed. However, if these components are subjected to severe use, grease zerks have been provided for additional lubrication at the user's discretion.

Item Lube Capacity at

Engine Oil PS-4 PLUS

Brake Fluid DOT 4 Only --- See page 32.

Transmission Oil Polaris AGL Syn-

Demand Drive Fluid (Front Gearcase)

ADC Fluid Polaris ADC Fluid --- See page 90.

Front Prop Shaft Yoke

Performance Synthetic 2W-50

thetic Gearcase Lube

Demand Drive LT Premium Fluid

Polaris Premium U-Joint Lube

Fluid Change

2 qt. (1.9 l) See page 80.

32 oz. (948 ml) See page 88.

9.3 oz. (275 ml) See page 89.

--- Grease fittings (3 pumps

Inspection Procedure

maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.

MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Synthetic 2W-50 4-cycle oil or a similar oil for this engine. See page 79.

Oil may need to be changed more frequently if Polaris oil is not used. Always use 2W-50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 133 for the part numbers of Polaris products.

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

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

Engine Oil

Dipstick

Safe

Add Oil

{

Safe Range

Oil Level (500 EFI)

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

Tip: A rising oil level between checks in

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

1. Position the vehicle on a level

surface.

2. Start the engine. Allow it to idle

for 20-30 seconds. Stop the engine.

3. Remove the dipstick. Wipe it

dry with a clean cloth.

4. Reinstall the dipstick

completely.

5. Remove the dipstick and check

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

6. Reinstall the dipstick securely.

MAINTENANCE

Dipstick

Safe

Add Oil

{

Safe

Range

Check Level

on Top Side

Engine Oil

Oil Level (800 EFI)

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

1. Position the vehicle on a level

surface.

2. Lift the lever lock to remove

the dipstick. Wipe it dry with a clean cloth.

3. Reinstall the dipstick com-

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

4. Remove the dipstick and check

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

Tip: Due to the dipstick entry angl e into

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

5. After reinstalling the dipstick,

seat the lever lock.

MAINTENANCE

Drain

Plug

Screen

Fitting

New Sealing Washer

Alignment Mark

Engine Oil

Oil and Filter Change (500 EFI)

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75.

1. Position the vehicle on a level surface.

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

3. Stop the engine.

4. Clean the area around the drain

plug.

5. Place a drain pan under the oil

tank.

6. Remove the drain plug. Allow

the oil to drain completely.

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

7. Install a new sealing washer on

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

8. Reinstall the drain plug. Torque

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

9. Disconnect the lower oil deliv-

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

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

tape.

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

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

Tip: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34

Nm).

11. Reattach the oil line.

MAINTENANCE

Engine Oil

Oil and Filter Change (500 EFI)

12. Place shop towels beneath the oil

filter. Using an oil filter wrench, turn the filter counterclockwise to remove it.

13. Make sure the o-ring from the old

filter is completely removed from the engine. Using a clean dry cloth, clean the filter sealing surface on the crankcase.

14. Lubricate the o-ring on the new filter with a film of fresh engine oil.

Check to make sure the o-ring is in good condition.

15. Install the new filter and rotate it clockwise by hand until the filter

gasket contacts the sealing surface, then turn it an additional 1/2 turn.

16. Approximately one cup of engine oil will remain in the crankcase.

To drain, remove the drain plug on the lower right side of the crankcase.

17. Reinstall the drain plug. The sealing surfaces on the drain plug and

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

18. Torque to 14 ft. lbs. (19 Nm).

19. Remove the dipstick.

20. Add two quarts (1.9 l) of recommended oil. If the sump is not

drained, add about 1 3/4 quarts (1.6 l) initially.

21. Reinstall the dipstick.

22. Place the transmission in PARK.

23. Lock the parking brake.

24. Prime the oil pump using the procedure on page 85. Then stop

the engine and inspect for leaks.

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

mark on the dipstick.

26. Dispose of used filter and oil properly.

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

(5 cm)

Engine Oil

Oil and Filter Change (500 EFI)

Oil Pump Priming

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

1. Clamp or pinch off the vent line

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

2. Start the engine. Allow it to idle

for 10-20 seconds.

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

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

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

MAINTENANCE

Drain Plug Location

to front

Engine Oil

Oil and Filter Change (800 EFI)

Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Always change the oil filter whenever changing oil.

1. Position the vehicle on a level surface.

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

utes.

3. Stop the engine.

4. Clean the area around

the drain plug.

5. Place a drain pan

under the crankcase.

6. Remove the drain

plug. Allow the oil to drain completely.

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

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

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

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

MAINTENANCE

Engine Oil

Oil and Filter Change (800 EFI)

9. Place shop towels beneath the oil fil-

ter. Using an oil filter wrench (available from your Polaris dealer), turn the filter counterclockwise to remove it.

10. Using a clean dry cloth, clean the fil-

ter sealing surface on the crankcase.

11. Lubricate the o-ring on the new filter

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

12. Install the new filter and rotate it clockwise by hand until the filter

gasket contacts the sealing surface, then turn it an additional 1/2 turn.

13. Remove the dipstick.

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

15. Place the transmission in PARK.

16. Lock the parking brake.

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

18. Stop the engine.

19. Check for leaks.

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

mark on the dipstick.

21. Dispose of used filter and oil properly.

MAINTENANCE

Drain Plug

Fill Plug

Transmission Oil

Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Maintain the oil level at the bottom of the fill plug hole threads. We recommend the use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page 133 for the part numbers of Polaris products.

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

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

Transmission Oil Level

1. Position the vehicle on a level

surface.

2. Remove the fill plug.

3. Check the oil level. Add the

recommended oil as needed.

4. Reinstall the fill plug. T orque

to 20-25 ft. lbs. (27-34 Nm).

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Transmission Oil

Transmission Oil Change

1. Remove the fill plug.

2. Place a drain pan under the

gearcase.

3. Remove the drain plug. Allow

the oil to drain completely.

4. Clean and reinstall the drain

plug. T orque to 20-25 ft. lbs. (27-34 Nm).

5. Add 32 oz. (948 ml) of the

recommended oil.

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

7. Check for leaks. Dispose of used oil properly.

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. We recommend the use of Demand Drive LT Premium Fluid. Use of other fluids may result in improper operation of components. See page 133 for the part numbers of Polaris products.

Maintain the fluid level at the bottom of the fill hole threads. See below for capacity.

The fill plug is located on the right side of the demand drive unit. The drain plug is located on the bottom right side of the unit.

Demand Drive Capacities

Demand Drive with ADC 9.3 oz. (275 ml)

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Level

1. Position the vehicle on a level surface.

2. Remove the fill plug. Check the fluid level.

3. Add the recommended demand drive fluid 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).

Fluid Change

1. Position the vehicle on a level surface.

2. Remove the fill plug.

3. Place a drain pan under the demand drive unit.

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

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

6. Add the recommended fluid. See page 89 for capacity. Maintain the

fluid level at the bottom of the fill hole threads.

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

8. Check for leaks.

9. Dispose of used fluid properly.

Active Descent Control (ADC) Fluid

Two fluid levels must be maintained on your vehicle, the demand drive fluid and the ADC fluid. See page 89 for demand drive fluid maintenance.

Check and change the ADC fluid level at the intervals outlined in the Periodic Maintenance Chart beginning on page 75. Maintain the fluid level between the minimum and maximum marks on the reservoir. We recommend the use of Polaris ADC Fluid. See page 133 for the part numbers of Polaris products.

NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in

the hydraulic system.

Active Descent Control (ADC) Fluid

ADC Fluid Reservoir

800 EFI

500 EFI

Fluid Level

1. Open the front box cover and pull open the

access door.

2. View the fluid level in the reservoir. If the

level is below the minimum mark, remove the cap and add the recommended fluid.

3. Reinstall the cap securely. Secure the

access door and box cover.

Fluid Change

1. Position the vehicle on a level surface.

Before performing the fluid change, allow the vehicle to sit for at least 30 minutes.

2. Thoroughly clean the areas around and on

the ADC reservoir and bleeder valves (one on each side of the differential).

3. Remove the reservoir cap and diaphragm

assembly. Use a shop towel or suction tool to remove debris from the fluid and reservoir. Debris in the reservoir may result in inadequate bleeding and reduced performance of the system.

4. Fill the reservoir to the maximum line with fresh ADC fluid.

5. Remove the protective caps from the bleeder valves.

6. Slowly loosen one of the valves (turn counter-clockwise) and allow

fluid and trapped air to flow from the fitting. Close the valve when clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops below the minimum fill line. Adding fluid to an empty reservoir will result in trapped air. If the level drops below the minimum line, add fluid to the maximum line and repeat step 6 before proceeding.

7. Torque the valves to 80 in. lbs. (9 Nm). Reinstall the valve caps.

8. Add fresh ADC fluid to the reservoir until the level is between the

minimum and maximum marks. Make sure the reservoir is free of debris.

9. Reinstall the cap securely. Clean up any drips or spills.

MAINTENANCE

Recovery

Bottle

Cooling System

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

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

Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air. Check the coolant level and maintain as recommended by adding coolant to the recovery bottle.

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 133 for the part numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located on the left side of the vehicle.

1. Remove the left side panel.

See page 96.

2. Maintain the coolant level

between the minimum and maximum marks on the bottle (when the fluid is cool).

3. Add coolant as needed.

MAINTENANCE

Radiator Cap

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine, Polaris recommends that you drain the system completely every two years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for maintenance or repair. If the recovery bottle has run dry, check the level in the radiator. Add coolant as needed.

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

1. Open the front box cover and

pull open the access door.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radiator filler neck.

4. Reinstall the pressure cap.

Use of a non-standard pressure cap will not allow the recovery system to function properly. Contact your dealer for the correct replacement part.

5. Secure the access door.

6. Secure the box cover.

MAINTENANCE

3/64" (1 mm)

Brakes

Hand Brake

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

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. To ensure proper diaphragm operation, always fill the reservoir as needed whenever the cover is loosened or removed. Do not overfill.

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

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.

1. Always keep brake fluid at an adequate

level. See page 32.

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. Replace brake pads when they are worn to 3/64" (1 mm).

5. Check the security and surface condition

of the disc.

Auxiliary Foot Brake

The hydraulic auxiliary brake system requires no adjustment. Check the brake fluid level frequently for the auxiliary brake system. See page 34.

MAINTENANCE

String

Stand

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle. The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

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

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string

between two stands as shown in the illustration. Position the stands so that the string is flush with the side of the rear tire. If available, you may use a long straightedge instead of string.

4. Measure the distance

from the string to the rim at the front (1) and rear (2) of the front rim. The rear measurement should be 1/16"-1/8" (2-3 mm) more than the front measurement on each side of the vehicle to obtain the recommended 1/8" to 1/4" (3-6 mm) toe out alignment.

5. Repeat the measurement procedure on the other side of the vehicle.

6. If you discover improper alignment, see your Polaris dealer for ser-

vice.

MAINTENANCE

Step 1 Step 2 Step 3

Screws

Rivets

Steering Assembly

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

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. Pull the panel downward and rearward to remove it.

3. When reinstalling side panels, align the fasteners and press firmly to

secure them.

Footwell Removal

1. Remove the six screws on

the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the plastic rivets securing the footwell to the fenders.

3. Remove the footwell.

MAINTENANCE

WARNING

1/8" (3 mm)

Tires

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. Always follow all tire maintenance procedures as outlined in this manual and on the labels on the vehicle. Always use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 134 for recommended tire type, size and pressure.

Tire Tread Depth

Always replace tires when tread depth is worn to 1/8" (3 mm) or less.

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.

Wheel Removal

1. Stop the engine.

2. Place the transmission in PARK.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

WARNING! Do not service axle nuts that have a cotter pin installed. See your Polaris dealer.

5. Elevate the side of the vehicle by placing a suitable stand under the

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

Polaris Sportsman 800 X2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual