Polaris Sportsman 9921837 User Manual

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)

• Quadricycles/Tractors

• RANGER utility vehicles

• Victory motorcycles
Always follow the instructions and recommendations in this manual.

The manual contains instructions for minor maintenance, but informa­tion about major repairs is outlined in the Polaris Service Manual and
should be performed only by a Factory Certified Master Service Dealer
(MSD) Technician. Please see your dealer for all of your service needs
during (and after) the warranty period.

For more information about Polaris, visit us online at
www.polarisindustries.com.

1

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 inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2009 Sportsman 500 EFI Tractor Owner’s Manual
P/N 9921837

2

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 20

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Emission Control Systems . . . . . . . . . . . . . . . 60

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 116

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 118

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 119

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 126

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

3

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.

4

INTRODUCTION

WARNING

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

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

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

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

• This vehicle is approved for OFF-ROAD TOWING ONLY. Operating a Tractor/
trailer combination on public roads is prohibited. See your Polaris dealer
about configuring the vehicle to be certified to tow a trailer on-road.

5

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

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: ___________________________________________________________

6

SAFETY

Safety Training

When you purchased your new Tractor, your dealer offered a hands-on
safety training course. You were also provided with printed materials
that explain safe operating procedures. Review this information on a
regular basis.

If you purchased a used Polaris Tractor from a party other than a Polaris
dealer, please request free safety training from any authorized Polaris
dealer.

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

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

Equipment Modifications

The warranty on your Polaris Tractor may be terminated if any equip­ment has been added, or if any modifications have been made, that
increase speed or power. The addition of certain accessories, including
(but not limited to) mowers, blades, tires, sprayers and large racks may
change vehicle handling. Use only Polaris-approved accessories. Know
their function and effect on the vehicle.

7

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

Safe Riding Gear

Always wear protective clothing to reduce the chance of injury.

Helmet

Always wear a helmet that meets or exceeds established safety stan­dards.

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

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

8

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.

9

SAFETY

WARNING

<

1

6

1

6

1

6

Rider Safety

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

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

Never operate a Tractor without proper instruction.
Take a training course. Beginners should receive
training from a certified instructor. Contact an
authorized Polaris Tractor dealer or visit the Polaris
web site at www.polarisindustries.com.

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

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

Gasoline is highly flammable and explosive under certain conditions.

• Use extreme caution whenever handling gasoline.

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

• Never fill a fuel container while it's on the vehicle. Static electricity between
the rack and container could cause a spark.

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

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

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

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

10

Rider Safety

Never carry a passenger on this vehicle.

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

Never consume alcohol or drugs before or
while operating a Tractor.

SAFETY

Never operate at excessive speeds. Travel
and turn at speeds appropriate for the terrain,
visibility, operating conditions and your
experience.

11

SAFETY

Rider Safety

Always inspect your Tractor before each
use to verify that it's in safe operating
condition. Follow the inspection and
maintenance procedures outlined in this
manual. See page 41.

Keep both hands on the handlebars. Keep
both feet on the footrests.

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

Always follow the procedures outlined in
this manual for turning. See page 45.

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

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

12

Rider Safety

Never attempt jumps or other stunts.

Always follow the procedures outlined in this
manual for driving on hills. See page 46.
Never operate on hills too steep for the
Tractor or for your abilities. Practice on
smaller hills before attempting larger hills.
Avoid climbing hills steeper than 25°.

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

Always follow the procedures outlined in this
manual for driving downhill and for braking
on hills. See page 49.

SAFETY

Always follow the procedures outlined in this
manual for crossing the side of a hill. See
page 48.

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

Use the front hitch for vehicle recovery or
towing only. Always remove the front hitch
before operating in forward gear. See page

26.

13

SAFETY

Rider Safety

Always follow the procedures outlined in this
manual for braking if you stall or roll
backwards while climbing a hill. Never back
down a hill. See page 50.

Always follow the procedures outlined in this manual for operating over
obstacles. See page 55.

Always follow the procedures outlined in this
manual for operating on slippery or loose
surfaces. Use extra caution. Always avoid
skidding or sliding. See page 54.

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

52.

14

SAFETY

Rider Safety

Always follow the procedures outlined in this manual for driving in reverse. See
page 56.

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

Never modify a Tractor through
improper installation or use of
accessories.

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

15

SAFETY

Rider Safety

Never operate the Tractor on a frozen body of water.

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

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

Always unlock the steering before starting the engine. See page 26.

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

For more information about Tractor safety,

contact an authorized Polaris Tractor dealer or visit the

Polaris web site at www.polarisindustries.com.

16

SAFETY

+

General

Alert

+

Hill Operation

and Hitch Alert

+

Age 16 Alert

<

1

6

1

6

1

6

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If a 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.

The following pages repeat the information found on each label.

General Alert
(Multi-Lingual)

Before you operate this
vehicle, read the
owner’s manual.

7173025

Hill Operation/Hitch Alert

• Never operate this vehicle on HILLS steeper than 25 degrees 25°.

• To prevent flip-over on hilly terrain, when going up or down, use throttle and

brakes gradually.

7175814

17

SAFETY

+

Reverse Override

Alert

+

“No Passenger”

Warning

+

+

Rack

Warning

Rack

Warning

Tire Pressure/

Load Alert

+

+

Clutch

Cover Alert

Safety Labels and Locations

Tire Pressure/Load Alert

TIRE PRESSURE IN PSI (kPa): FRONT 5 (34.5) REAR 5 (34.5)
MAXIMUM WEIGHT CAPACITY 420 LBS. (191 kg)
INCLUDES WEIGHT OF OPERATOR, CARGO AND ACCESSORIES.
Read Owner's Manual for more detailed loading information.

7174877

Reverse Override Alert/4X4 (AWD) Switch

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

traction if too much throttle is applied. Loss of control or forward flipover may
result, especially in 4X4 (AWD). See Owner's Manual.

4X4 (AWD) SWITCH
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This

may cause severe drive shaft and clutch damage. See your Owner’s Manual.

18

7175106

SAFETY

Safety Labels and Locations

“No Passenger” Warning

WARNING
NEVER ride as a passenger.
Passengers can cause a loss of control, resulting in

SEVERE INJURY or DEATH.

7175378

Clutch Cover Alert

NO STEP

7173030

Rack Warning

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.

• Max. Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)

7172572

19

FEATURES AND CONTROLS

Horn Switch

Hazard

Switch

Main Key Switch

Engine Stop Switch

Headlight

Switch

4X4 Switch

Turn Signal Switch

Mode/Reverse

Override Switch

Master Light

Switch

Switches

Master Light Switch

The master light switch must be in the ON position to allow operation of
the headlights, parking lights and taillights.

Mode/Reverse Override Switch

Press the switch to toggle through the speedometer display modes
(except in reverse). See page 31.

To gain additional power while operating in reverse, press the override
switch before opening the throttle. This will cancel the reverse speed
limit function. The override switch also allows activation of 4X4 in
reverse, if the 4X4 switch is on.

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

20

FEATURES AND CONTROLS

Engine

Stop Switch

Light

Switch

Switches

Main Key Switch

End all electrical power to the vehicle.

The LIGHTS ON position turns the headlights
on. The master light switch must be on and the

engine stop switch must be in the RUN position.

Start the engine. The headlights are not on in
this position.

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

position.

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

Engine Stop Switch

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

OFF (STOP)

RUN

Light Switch (High/Low Beam)

Use the light switch to change the
headlights from high beam to low
beam. The master light switch must
be on to operate the headlights.

High Beam

Low Beam

21

FEATURES AND CONTROLS

4X4 Switch

Tu r n

Indicators

Hazard Warning

Switch

Horn Switch

Turn Signal

Switch

Switches

4X4 Switch

Use the 4X4 switch to engage
ADC 4X4, 4X4 or 2X4. See
page 28.

Hazard Warning Switch

Push the hazard warning
switch to cause all turn

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

Turn Signal Switch

Push the toggle switch
either left or right to

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

Horn Switch

Press the horn switch to sound the horn.

22

FEATURES AND CONTROLS

Electronic Throttle Control

Mirrors

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

Throttle Lever

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

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

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

Release the lever to reduce engine
speed and vehicle movement.

Electronic Throttle Control (ETC)

ETC causes the engine to
stop if the throttle cable
sticks in an open position
when the operator releases
the throttle lever.

The Electronic Throttle Control (ETC) stops the engine in the event of a throttle
system malfunction. Do not modify this safety feature or replace it with other
throttle mechanisms.

23

FEATURES AND CONTROLS

Foot Brake

Brakes

Aggressively applying the brakes when backing down a hill may cause rear
tipover. Aggressively applying the brakes while moving forward may cause the
rear wheels to skid and result in loss of control. Read this owner's manual and
understand the operation of all brake systems on this vehicle. Always use
caution whenever applying the brakes.

Foot Brake

The all-wheel foot brake is located on the
right footrest. The foot brake operates both
front and rear brakes. Press the brake pedal
down with your foot to apply the all-wheel
brakes. If the rear wheels begin to skid or
slide while using the foot brake, reduce
brake pressure.

Hand Brake Lever

The hand brake operates both front and rear
brakes. Squeeze the brake lever toward the
handlebar to apply the all-wheel brakes. If
the rear wheels begin to skid or slide while
using the brake, reduce lever pressure.

Parking Brake

1. Place the transmission in PARK.

2. Squeeze the brake lever toward the han-

dlebar. Push the parking brake lock for­ward to engage the lock. Release the
brake lever.

3. To release the parking brake lock,

squeeze and release the brake lever.

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

24

FEATURES AND CONTROLS

Load Adjuster

Measure Preload

(shown with seat removed)

Height Adjustment Slots

Backrest Knobs

Seat

Seat Load Adjustment

Adjust the seat spring for the comfort
of a lighter or heavier operator. Reach
under the rear rack to access the
adjuster. Tighten the spring for heavier
riders. Loosen the spring for lighter rid­ers.

Use the following table to determine
the best preload measurement for rider
weight. Measure preload between the
adjuster plate and the lower spring
retainer.

Rider Weight

Up to 39 kg 0 mm

39-94 kg 0-32 mm

Over 94 kg 32-64 mm

Driver's seat, type Seat One:

e11*78/764*2006/96*2056*00

Seat Removal

Lift the latch bar at the rear of the seat to
release the latch. Tilt the seat slightly rear­ward to disengage the seat tabs from the
rear seat base slots. Remove the seat.

Make sure the seat is securely installed
before operating.

Seat Height Adjustment

To raise or lower the seat, remove the seat
and reposition the seat tabs in one of the
rear seat base slots. Make sure the seat is
securely installed before operating.

Backrest Adjustment

Loosen the backrest knobs on each side of
the backrest mount and slide the backrest
forward or rearward to the desired posi­tion. Tighten the knobs securely.

Preload

Measurement

25

FEATURES AND CONTROLS

Steering Lock

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

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

1. Turn the handlebars to the full right

position. The handlebars may also be
locked in the full left position.

2. Insert the steering lock key and turn it

clockwise. Remove the key.

3. Place the steering lock keys in a safe

place. The lock must be replaced if the
keys are lost.

4. Reverse the procedure to unlock the steering.

Hitches

See page 116 for hitch weight capacities.

Front Hitch

Use the front hitch for vehicle recovery or towing only. Do not use the
front hitch for any other purpose. Always remove the front hitch before
operating in forward gear.

Rear Hitch

Hitch specifications may differ from vehicle capacity specifications. Do
not exceed the hitch and towing capacities specified for this vehicle. See
page 116.

Use the rear hitch for towing a trailer. See pages 57-59 for procedures.

Rear Hitch Specifications

Material 1021 M Steel
Fasteners 1008K Steel (Main Pin and Receiver Pin)
Weld Length and Positions 3 mm fillet, both sides, all around
Maximum Vertical Load 75 kg (on coupling point)
Maximum Towable Mass 750 kg
Approval # e11*89/173*2006/26*2073*xx

26

FEATURES AND CONTROLS

Step 2Step 1 Step 3

Gear

Selector

Fuel Tank

Cap

Hitches

Hitch Installation/Removal

1. Release the wire lock from the 12.7 mm pin and remove the pin.

2. Install the hitch to the receiver.

3. Install the 12.7 mm pin through the bore of both the receiver and the

hitch. Secure the wire lock. Make sure the hitch assembly is secure
at that the wire lock is properly engaged over the pin.

4. To remove the hitch, release the wire lock, remove the hitch, rein-

stall the pin to the receiver and secure the wire lock.

Automatic Transmission Gear Selector

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

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

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

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

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

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 of 87. Do not use E-

85 fuel.

27

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

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

ADC 4X4

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 30.

4X4

When the switch is on 4X4,
the vehicle 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.

The override switch allows activation of 4X4 in reverse if the 4X4
switch is on. See page 20.

2X4

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

28

FEATURES AND CONTROLS

All Wheel Drive (4X4) System

Engaging 4X4

The 4X4 switch may be turned on or off while the vehicle is moving.
4X4 will not engage until engine speed is below 3100 RPM. 4X4
remains engaged until the switch is turned off. There is no limit to the
length of time the vehicle may remain in 4X4.

If the switch is turned off while the demand drive unit is engaged, it will
not disengage until the rear wheels regain traction. Engage 4X4 before
getting into situations where maximum traction is 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.

29

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 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 24 km/h

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

30

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

The instrument cluster senses vehicle speed from the transmission. In
addition to showing vehicle speed, the speedometer needle flashes when
a warning condition exists.

The instrument cluster measures distance in miles or kilometers, as well
as hours of operation. It also includes a reverse speed limiter function
that limits the vehicle's speed to approximately 11-14 km/h. Refer to
page 20 for additional information.

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

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

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

31

FEATURES AND CONTROLS

1

2

34

5

6

8

7

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

6. 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.

7. 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 vehicle if
this warning appears. Serious engine damage could result.

8. Mode Indicator

32

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 20. The transmission
cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles or kilometers traveled by the Tractor.

Trip Meter Mode

The trip meter records the miles or kilometers traveled by the Tractor 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

34.

33

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. Do not turn

the key switch off until the display stops flashing or the new setting
will not be locked into the memory.

34

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 4X4
coil (only on models with switchable 4X4). 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 36.

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

35

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. If you scroll past the intended number, press and hold the
button until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

36

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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.

Downloading Codes

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

See page 39 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.

37

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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. 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

38

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
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
61 END SEQUENCE

Failure Description

39

OPERATION

Break-In Period

The break-in period for your new Polaris Tractor 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 will increase the life and performance of
your Tractor more than 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.

Do not operate at full throttle or high speeds for extended periods during
the first three hours of use.

Engine and Drivetrain Break-in

1. Fill the fuel tank with the recommended fuel. See page 27.

2. Check the engine oil level. See page 66. Add oil if necessary.

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

vehicle operation and handling.

4. Drive slowly. 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 41.

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)

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.

40

OPERATION

Pre-Ride Checklist

Item Remarks Page

Hand brake/lever travel Ensure proper operation 83

Foot brake Ensure proper operation 83

Brake fluid Ensure proper level 83

Front suspension Inspect, lubricate if necessary 65

Rear suspension Inspect, lubricate if necessary 65

Steering/steering lock Unlock the steering; ensure free oper-

Steering Ensure free operation -

Tires Inspect condition and pressure 88

Wheels/fasteners Inspect, ensure fastener tightness 88

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 27

Coolant level (if applicable) Ensure proper level 78

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 23

Indicator lights/switches Ensure operation 20

Engine stop switch Ensure proper operation 21

Mirrors Adjust for best side/rear vision 23

Air filter, pre-filter Inspect, clean 90

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 76

Front Hitch Remove the front hitch (if installed) 26

ation

tric grease when lamp is replaced

tric grease when lamp is replaced

protective clothing

26

89

66

79

87

93

94

8

41

OPERATION

Starting the Engine

NOTICE: Operating the vehicle immediately after starting could cause engine

1. Position the vehicle on a level

2. Place the transmission in PARK

3. Sit on the vehicle.

4. Apply the brakes.

5. Move the engine stop switch to

6. Do not press the throttle while

7. Turn the ignition key past the PARKING

8. If the engine does not start, release the

9. Repeat steps 7 and 8 until the engine

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

surface.

(or neutral).

RUN.

starting the engine.

LIGHTS ON position to engage the
starter. Activate the starter for a maxi­mum of five seconds, releasing the key
when the engine starts.

starter and wait five seconds.

starts.

42

OPERATION

Cold Weather Operation

Internal engine condensation increases as outside temperatures
decrease. If the vehicle is used year-round, check the oil level fre­quently. A rising oil level could indicate condensation in the bottom of
the oil tank, which can lead to engine damage. Any condensation must
be drained.

Always operate the engine long enough to reach operating temperature,
which reduces condensation. See your Polaris dealer for engine heater
kits, which provide quicker warm-ups and easier starting in cold
weather.

PVT Operation

When To Use Low Range and High Range

Condition Range to Use

Operating at speeds less than 11 km/h Low

Towing heavy loads Low

Operating in rough or rugged terrain Low

Operating at speeds greater than 11 km/h High

43

OPERATION

Driving Procedures

1. Wear protective riding gear. See page 8.

2. Perform the pre-ride inspection. See page 41.

3. Sit upright. Keep your feet on the footrests. Keep both hands on the

handlebars.

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

5. Apply the brakes.

6. Shift the transmission into gear.

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

8. Release the brakes.

9. Slowly squeeze the throttle lever toward the handlebar to begin

driving.

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

brakes on level surfaces.

44

Turning the Vehicle

1. Before turning, activate

a turn signal to alert oth­ers of your intentions.
Activate the left signal
before a left turn. Acti­vate the right signal
before a right turn.

2. Steer in the direction of

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

3. Never turn quickly when

carrying cargo.

4. Practice making turns at

slow speeds before
attempting to turn at
faster speeds.

OPERATION

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

45

OPERATION

25° Maximum

Driving Uphill

Whenever traveling uphill, follow these precautions:

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

descending a hill. See page 30.

2. Avoid steep hills (25° maximum).

3. Avoid hills with slippery or loose surfaces.

4. Keep both feet on the footrests.

5. Shift body weight uphill.

6. Drive straight uphill.

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

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

dismounting quickly.

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

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

46

OPERATION

Driving Uphill

If all forward speed is lost:

Keep your weight uphill.

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

1. Apply the brakes gradually.

2. When fully stopped, lock the hydraulic parking brake.

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

pointed straight uphill.

4. Use the K-turn to turn around. See page 50.

Always follow the procedures outlined in this
manual for climbing hills. Avoid climbing hills
steeper than 25°.

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

47

OPERATION

Driving on a Sidehill (Sidehilling)

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

1. Slow down.

2. Avoid hills with slippery or loose surfaces.

3. Avoid crossing the sides of steep hills.

4. Shift your weight uphill.

5. Keep 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!

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

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

48

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

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

descending a hill. See page 30.

2. Avoid steep hills (25° maximum).

3. Avoid hills with slippery or loose surfaces.

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

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

can cause the vehicle to pitch sharply to one side.

6. Shift your weight rearward.

7. Apply the brakes slightly to aid in slowing.

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

49

OPERATION

2.4 m

Turning Around on a Hill (K-Turn)

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

1. Stop the vehicle. Keep your weight uphill.

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

descending a hill. See page 30.

3. Lock the hydraulic parking brake.

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

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

pointed straight uphill.

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

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

8. Slowly release the brake lever and allow the vehicle to roll around

50

to your right until it's pointing across the hill or slightly downward.

OPERATION

Turning Around on a Hill (K-Turn)

9. Lock the hydraulic parking brake.

10. Remount from the uphill side. Keep your weight uphill.

11. Apply the foot brake.

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

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

14. Release the foot brake and drive slowly downhill. Control speed

with either the hand or foot brake until the vehicle is on level
ground.

Always follow the procedures outlined in this
manual for climbing hills. Avoid climbing hills
steeper than 25°.

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

51

OPERATION

Maximum

Depth

Driving Through Water

Follow these procedures when driving through water:

1. Check water depth and current before crossing.

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

3. Drive slowly. Avoid rocks and obstacles.

4. Avoid operating in water deeper than the bottom of the footrests. If

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

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

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

52

OPERATION

Driving Through Water

If your vehicle becomes fully immersed, and it's impossible to take it to
a dealer before starting it, follow the steps described on page 98. Have
the vehicle serviced by your dealer promptly.

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

If the vehicle stops while fully submerged, major engine damage can result if the
machine is not thoroughly inspected. Take the vehicle to your dealer before
starting the engine.

53

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

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

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

1. Slow down before driving onto slippery surfaces.

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

3. Be alert. Watch the trail.

4. Avoid quick, sharp turns.

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

and shifting your body weight forward.

6. Never apply the brakes during a skid.

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

54

wheels are spinning. Engage 4X4 when the wheels have traction.

OPERATION

Driving Over Obstacles

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

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

3. Never operate over large obstacles.

4. Avoid hazards such as logs, rocks and low branches.

Parking on an Incline

Avoid parking on an incline.
If it's unavoidable, follow

these precautions:

1. Stop the engine.

2. Place the transmission

in PARK.

3. Always block the rear

wheels on the downhill
side.

55

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

1. Always check for obstacles or people behind the vehicle before

backing.

2. Avoid backing downhill.

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

4. Avoid turning at sharp angles.

5. Never open the throttle suddenly.

6. Do not use the override switch unless additional power is required

for vehicle movement. Use with caution.

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

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

56

OPERATION

Hauling Cargo

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

• Read and understand the load distribution warnings listed on the vehicle

warning labels.

• NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of
the operator, accessories, loads in the racks and the load on the trailer
tongue. The combined weight of these items must not exceed the maximum
weight capacity.

• REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING

WHEN HAULING CARGO OR TOWING. Use extreme caution when applying
brakes. Avoid situations that require backing downhill.

• When operating over rough or hilly terrain, reduce speed, cargo and towed

load to maintain stable driving conditions.

• DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on

the front rack.

• CARRY LOADS AS LOW ON THE RACK AS POSSIBLE. Carrying a load

high on the rack raises the center of gravity of the vehicle and creates a less
stable operating condition. Reduce load weight when cargo is high. Secure
off-centered loads that cannot be centered and operate with extra caution.

• CARRYING A LOAD on only one rack may cause the vehicle to overturn.

Split the load between the front rack and rear rack, with 1/3 in the front and 2/
3 in the back. Do not exceed load capacities. See specifications beginning on
page 116.

• SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the
vehicle.

• OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

handling off-centered loads that cannot be centered, securely fasten the load
and operate with extra caution. Always attach the tow load to the hitch point
designated for your vehicle.

• USE EXTREME CAUTION when operating with loads that extend over the

rack sides. Stability and maneuverability may be adversely affected, causing
the vehicle to overturn.

• TOWING is approved OFF-ROAD ONLY. Operating a Tractor/trailer

combination on public roads is prohibited.

• TOWING SPEED should never exceed 16 km/h. Never exceed 8 km/h when

towing loads in rough terrain, while cornering, or while ascending or
descending hills.

57

OPERATION

1/3

2/3

Hauling Cargo

Always read and understand the load distribution warning labels on the
vehicle. Never exceed the weight capacities specified for this vehicle.

Towing Loads

Towing is approved OFF-ROAD ONLY. Operating a Tractor/trailer
combination on public roads is prohibited. See your Polaris dealer about
configuring the vehicle to be certified to tow a trailer on-road. Do not
tow any trailer on a grade steeper than 15°.

• Use the front hitch for vehicle recovery or towing only. Always
remove the front hitch before operating in forward gear.

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

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

Capacities Rear Hitch Front Hitch

Maximum Towed Load (Level Ground) 557 kg 386 kg

Maximum Vertical Hitch Weight 55 kg 39 kg

58

Hauling Cargo

Maximum

10 cm

Towing Loads

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

OPERATION

59

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

Spark Arrestor

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

Exhaust Emission Control System

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

Electromagnetic Interference

This spark ignition system complies with USA requirements, Canadian
ICES-002 and EMC requirements of European directives 97/24/EC and
2004/108/EC.

60

MAINTENANCE

Periodic Maintenance Chart

Maintenance intervals in the following chart are based upon average
riding conditions. Vehicles subjected to severe use must be inspected
and serviced more frequently.

The programmable service interval mode on the instrument cluster will
help determine when maintenance service is due. See page 31.

Record maintenance and service in the Maintenance Log beginning on
page 126.

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.

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.

61

MAINTENANCE

Periodic Maintenance Chart

Improperly performing the procedures marked with a  could result in
component failure and lead to serious injury or death. 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

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 need

Front suspension - Pre-Ride -

Rear suspension - Pre-Ride -

Tires - Pre-Ride -

Brake fluid level - Pre-Ride -

Brake lever - Pre-Ride -

Foot brake - Pre-Ride -

Brake system - Pre-Ride -

Passenger seat
lock-out

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

X Engine oil level - Pre-Ride -
XEAir filter, pre-filter - Daily - Inspect; clean often; replace

X Air box sediment

tube

Coolant - Daily - Check level daily, change

X ADC fluid - Daily - Check level daily, add as

Headlight/taillight - Daily - Check operation; apply

(whichever comes first)

Hours Calendar Kilometers

ed. See Pre-Ride Checklist
on page 41.

-Pre-Ride -

as needed

- Daily - Drain deposits when visible

coolant every 2 years

needed

dielectric grease if replacing
lamps

Remarks

62

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

Brake pad wear 10 Monthly 160 Inspect periodically

X

Q

Battery 20 Monthly 320 Check terminals; clean; test

X Demand drive fluid 25 Monthly 400 Inspect level; change yearly
X Rear gearcase oil

(if equipped)

X Transmission oil 25 Monthly 400 Inspect level; change yearly
XEEngine breather

filter (if equipped)

X Engine oil change

(break-in)

X General

lubrication

Shift linkage 50 6 M 800 Inspect, lubricate, adjust

Q

Steering 50 6 M 800 Lubricate

X Front suspension 50 6 M 800 Lubricate
X Rear suspension 50 6 M 800 Lubricate

Q

Throttle cable/

E

ETC switch

E Throttle body

intake duct

Drive belt 50 6 M 800 Inspect; adjust; replace as

Cooling system 50 6 M 1600 Inspect coolant strength

X Engine oil change 100 6 M 1600 Perform a break-in oil change

X Oil filter change 100 6 M 1600 Replace with oil change
X Oil tank vent hose

(if equipped)

(whichever comes first)

Hours Calendar Kilometers

- Weekly - Inspect; replace as needed

25 Monthly 400 Inspect level; change yearly

25 Monthly 400 Inspect; clean if needed

- 1 M - Perform a break-in oil change

50 3 M 800 Lubricate all fittings, pivots,

50 6 M 800 Inspect; adjust; lubricate;

50 6 M 800 Inspect duct for proper seal-

100 6 M 1600 Inspect routing, condition

at one month

cables, etc.

replace if necessary

ing/air leaks

needed

seasonally; pressure test
system yearly

at one month

Remarks

63

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

Q

Valve clearance 100 12 M 1600 Inspect; adjust

E

Q

Fuel system 100 12 M 1600 Check for leaks at tank cap,

E

X Radiator 100 12 M 1600 Inspect; clean external

X Cooling hoses 100 12 M 1600 Inspect for leaks
X Engine mounts 100 12 M 1600 Inspect

Exhaust muffler/
pipe

Q

Spark plug 100 12 M 1600 Inspect; replace as needed

E

X Wiring 100 12 M 1600 Inspect for wear, routing,

Q

Clutches (drive
and driven)

Q

Front wheel
bearings

Q

Brake fluid 200 24 M 3200 Change every two years

Q

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

Fuel filter 200 24 M 3200 Replace every 2 years, more

X

Q

E

Spark arrestor 300 36 M 4800 Clean out

Q

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 Kilometers

lines, filter, pump; replace
lines every 2 years

surfaces

100 12 M 1600 Inspect

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

100 12 M 1600 Inspect; clean; replace worn

100 12 M 1600 Inspect; replace as needed

parts

often under severe use

when parts are replaced

Remarks

64

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Guide

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 61. 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 Performance

Brake Fluid DOT 4 Only --- See page 80.

Transmission Oil Polaris AGL Synthetic

Demand Drive
Fluid (Front
Gearcase)

ADC Fluid Polaris ADC Fluid --- See page 76.

Front Prop Shaft
Yoke

Synthetic 2W-50

Gearcase Lube

Demand Drive LT
Premium Fluid

Polaris Premium U-Joint
Lube

Fluid Change

2 qt. (1.9 l) See page 66.

32 oz. (948 ml) See page 72.

9.3 oz. (275 ml) See page 74.

--- Grease fittings (3

Method

pumps maximum)
every 800 km, before
long periods of stor­age, or after pressure
washing or submerg­ing.

65

MAINTENANCE

Engine Oil

Oil Recommendations

Always change the oil filter whenever changing oil.
Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. 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.

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

Oil Specifications

PS-4 PLUS Performance

Synthetic 2W-50 4-Cycle Oil

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

Lubricant Capacity Drain Plug Torque

1.9 liters 19-23 N-m

66

Engine Oil

Dipstick

Safe

Add Oil

Safe Range

{

Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Remove the dipstick.

Wipe it dry with a clean
cloth.

6. Reinstall the dipstick

completely.

MAINTENANCE

7. Remove the dipstick and check the oil level. Add oil as needed.

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

8. Reinstall the dipstick.

67

MAINTENANCE

Drain

Plug

New Sealing Washer

Screen

Fitting

Engine Oil

Oil and Filter Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Start the engine. Allow it to idle

for 30 seconds.

4. Stop the engine.

5. Clean the area

around the drain
plug.

6. Place a drain pan

under the oil tank.

7. Remove the drain

plug.

8. Drain the oil.

Hot oil may result in serious burns. Do not allow hot oil to contact skin.

9. Clean the drain plug. Reinstall the drain

plug with a new sealing washer.

10. Torque to specification. See page 66.

68

MAINTENANCE

Alignment Mark

Engine Oil

Oil and Filter Change

11. Disconnect the lower oil deliv-

ery hose and remove the screen
fitting from the oil tank. Clean
the fitting. Seal the fitting
threads with LOCTITE PST
505 or PTFE seal tape.

12. Reinstall the screen fitting and

rotate the fitting clockwise a
minimum of 2 1/2 turns into the
tank threads. Continue to rotate
the fitting until the nipple of the
fitting aligns with the mark on the tank. Do not over-tighten. Maxi-

mum torque for the screen fitting is 34 N-m.

13. Reattach the oil line.

14. Place towels under the oil filter.

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

15. Clean the filter sealing area on the

crankcase.

16. Lubricate the filter o-ring. Check to make

sure the o-ring is in good condition.

17. Install the new oil filter. After the filter

contacts the crankcase surface, turn it 1/2
turn by hand.

18. 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.

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

free of burrs, nicks or scratches.

19. Reinstall the drain plug. Torque to 19 N-m.

69

MAINTENANCE

Safe

Add Oil

Safe Range

{

Engine Oil

Oil and Filter Change

20. Remove the dipstick.

21. Add 1.9 liters of recommended

oil.

TIP: If the sump is not drained, add

about 1.6 liters initially.

22. Reinstall the dipstick.

23. Place the transmission in PARK.

24. Prime the oil pump using the procedure

on page 71.

25. Stop the engine. Check for oil leaks.

26. Check the oil level.

Add oil as needed.
Maintain the oil level
in the safe range. Do
not overfill.

27. Reinstall the dipstick.

28. Discard used oil and

filter properly.

70

MAINTENANCE

Clamp

Pressure

Relief Slit

Tank

5 cm

Engine Oil

Oil and Filter Change

Oil Pump Priming

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

1. Clamp the vent line 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. If you do not hear a rush of air, repeat the priming
procedure.

71

MAINTENANCE

Oil Level

Transmission Oil

Maintain the oil level at the bottom of the fill plug hole threads. Use the
recommended oil.

See page 118 for the part numbers of Polaris products.

Transmission Oil Recommendations

Lubricant Oil Change

Premium AGL Synthetic

Gearcase Lubricant

Capacity

948 ml 30 N-m 30 N-m

Transmission Oil Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Check the oil level. Add

the recommended oil as
needed. Do not overfill.

5. Reinstall the fill plug.

Torque to specification.

Fill Plug

To r q u e

Drain Plug

To r q u e

72

Transmission Oil

Transmission Oil Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill

plug.

4. Remove the drain

plug.

5. Drain the oil into a

drain pan.

6. Clean the drain

plug.

7. Reinstall the drain

plug. Torque to
specification. See
page 72.

8. Add the recommended oil. See

page 72.

9. Reinstall the fill plug. Torque to

specification. See page 72.

10. Check for leaks.

11. Discard used oil properly.

MAINTENANCE

73

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Fluid Recommendations

Gearcase Lubricant Capacity Fill Plug

Demand Drive

Unit

Demand Drive LT

Premium Fluid

275 ml 11-14 N-m 15 N-m

To r q u e

Use the recommended fluid.
Use of other fluids may
result in improper operation
of components. See page
118 for the part numbers of
Polaris products.

Maintain the fluid level at
the bottom of the fill hole
threads.

Fluid Level

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Add the recommended demand drive fluid as needed.

5. Reinstall the fill plug. Torque to specification.

Drain Plug

To r q u e

74

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the fill plug.

4. Remove the drain plug.

Drain the fluid into a drain
pan.

5. Clean the drain plug.

6. Reinstall the drain plug. Torque

to specification. See page 74.

7. Add the recommended fluid.

8. Reinstall the fill plug. Torque to

specification.

9. Check for leaks.

10. Discard used oil properly.

75

MAINTENANCE

ADC Fluid

Reservoir

Active Descent Control (ADC) Fluid

The ADC fluid reservoir is located under the front box. The reservoir
cap is yellow. We recommend the use of Polaris ADC Fluid. See page
118 for the part numbers of Polaris products.

Fluid Level

1. Position the vehicle on a level

surface.

2. Open the front box cover.

3. Open the access door.

4. View the fluid level in the

reservoir.

5. Remove the cap and add the

recommended fluid as needed.

DO NOT use brake fluid.

6. Maintain the fluid level

between the minimum and
maximum marks. Do not over­fill.

76

MAINTENANCE

Active Descent Control (ADC) Fluid

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.

TIP: Debris in the reservoir may result in inadequate bleeding and reduced per-

formance 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 N-m). 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.

77

MAINTENANCE

Cooling System

Any time the cooling system has been drained for maintenance or repair,
replace the coolant with a fresh mixture of antifreeze and water. Drain
the cooling system every two years. Add fresh coolant.

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 premixed and
ready to use. Do not dilute with water. See page 118 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

Some coolant level drop on new machines is
normal, as the system is purging itself of trapped
air. Add coolant as needed.

Check the coolant level in the radiator any time
the recovery bottle has run dry. Add coolant as
needed.

1. Check the coolant level when the

fluid is cool.

2. Remove the left side panel. See page

86.

3. View the coolant level. Maintain the

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

4. Add coolant as needed.

5. Reinstall the side panel.

78

MAINTENANCE

Radiator Cap

Cooling System

Radiator Coolant

Escaping steam can cause severe burns. Never remove the pressure cap while
the engine is warm or hot.

1. Open the front box cover.

2. Open the access door.

3. Remove the radiator pressure

cap.

4. If coolant is not visible,

slowly add coolant through
the radiator filler neck.

5. 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.

6. Secure the access door and

box cover.

79

MAINTENANCE

Brake Fluid

Check brake fluid levels for both brake systems before each ride.
Always maintain brake fluid at the recommended level. Do not overfill.

The brakes should feel firm when they're applied. Spongy or weak
brakes may indicate a fluid leak or low fluid level. A low fluid level
may also mean that brake pads are worn and need to be replaced. Do not
operate the vehicle with spongy or weak brakes. See your dealer for ser­vice.

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

If the fluid level is low add DOT 4 brake fluid only. See page 118 for the
part numbers of Polaris products.

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

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.

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

80

MAINTENANCE

Master

Cylinder

Indicator

Window

Full

Low

Brake Fluid

Hand Brake

The master cylinder is
located on the left handle­bar. Maintain the fluid level
6 mm below the top edge of
the master cylinder. Do not
overfill.

1. Position the vehicle on a

level surface. Make sure
the handlebars are straight.

2. View the fluid level

through the indicator win­dow (eye) 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.

3. Add the recommended fluid as needed. Do not overfill.

81

MAINTENANCE

Minimum

Maximum

Brake Fluid

Reservoir

Brake Fluid

Foot Brake

The foot brake fluid reservoir is located under the seat.

1. Position the vehicle on a level

surface.

2. Remove the seat.

3. View the fluid level in the

reservoir.

4. Remove the cap and add the

recommended fluid as needed.

5. Maintain the fluid level

between the minimum and
maximum marks. Do not
overfill.

6. Reinstall the reservoir cap.

7. Reinstall the seat.

82

MAINTENANCE

1 mm

Brakes

The front and rear brakes are hydraulic disc brakes, activated by apply­ing the foot brake. The handlebar brake is also hydraulic. Both brake
systems are self-adjusting.

Brake Inspections

Perform the following checks to keep the brake systems 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 80.

2. Check the brake systems regularly for

fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace the pads when
the friction material is worn to 1 mm.

5. Check the security and surface condition

of the disc.

83

MAINTENANCE

String

Stand

2

1

Toe Alignment

Do not attempt to adjust alignment. All steering adjustments should be
performed by an authorized Polaris dealer.

Use the following procedure to check the toe alignment of the vehicle.
The recommended toe alignment is 3-6 mm toe out.

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.

TIP: If available, you may use a

long straight-edge 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 2-3 mm more than the front mea­surement on each side of the vehicle to obtain the recommended 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.

84

MAINTENANCE

14-17 N-m

Adjuster

Steering Assembly

Check the steering assembly of the vehicle periodically for loose nuts
and bolts. If loose nuts and bolts are found, see your Polaris dealer for
service before operating the vehicle.

Handlebar Adjustment

The handlebars can be adjusted for rider preference.

Improper adjustment of the handlebars or incorrect torquing of the adjuster
block tightening bolts can cause limited steering or loosening of the handlebars,
resulting in loss of control. Follow the adjustment procedures exactly, or see
your Polaris dealer for service.

1. Remove the upper headlight pod.

2. Loosen the four handlebar bolts.

3. Adjust the handlebar to the desired

height.

4. Be sure the handlebars do not con-

tact the gas tank or any other part
of the machine when turned fully
to the left or right.

5. Torque the front two bolts to 14-17

N-m, then torque the rear two
bolts. A gap of up to 3 mm will
remain at the rear of the clamp
blocks.

Rear Spring

The rear shock absorber spring is
adjusted by rotating the adjuster
either clockwise or counterclockwise
to increase or decrease spring tension.

85

MAINTENANCE

Screws

Rivets

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel

near the rear cab.

3. With a firm motion, pull the

panel outward to disengage the
side panel from the grommet.

4. Pull the panel downward and

rearward to remove it.

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.

86

Throttle Cable Freeplay

Boot

Lock Nut

Adjuster

1.6-3.2 mm

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable adjuster

at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far
enough to expose the end of
the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1.6-3.2 mm of
freeplay is achieved at the
thumb lever. Move the throt­tle lever back and forth while
adjusting.

MAINTENANCE

5. Tighten the lock nut.

6. Squeeze the end of the

rubber boot and slide it
over the cable adjuster to
its original position.

7. Engine RPM should not increase when steering is turned full left or

right. Readjust cable freeplay if this occurs.

87

MAINTENANCE

3 mm

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident. 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 116 for recom­mended tire type, size and pressure.

Tire Tread Depth

Always replace tires
when tread depth is
worn to 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 Nut Torque Specifications

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

Nut Type Nut Torque

Lug Nut 122 N-m

2-Piece Flange Nut 37 N-m

88

Tires

Wheel Removal/Installation

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Loosen the wheel nuts

slightly.

4. Place a suitable stand under

the footrest frame to raise the
wheel slightly off the ground.

5. Remove the wheel nuts.

6. Remove the wheel.

7. Place the wheel on the hub.

8. Install the wheel nuts finger

tight.

9. Lower the vehicle to the

ground.

10. Torque the wheel nuts to

specification. See torque
chart on page 88.

MAINTENANCE

89

MAINTENANCE

Main Filter

Pre-Filter

Fuel Filter

The in-line fuel filter should be replaced by your dealer after every 100
hours of operation or annually. Do not attempt to clean the fuel filter.

Air Filter

Always clean and replace the air and breather filters at the intervals out­lined in the Periodic Maintenance Chart beginning on page 61.

1. Position the vehicle on a level

surface.

2. Place the transmission in PARK.

3. Remove the seat.

4. Release the air box

cover clips.

5. Remove the air

box cover.

6. Loosen the hose

clamp.

7. Remove the filter.

8. Remove the pre-filter

from the filter.

9. Wash the pre-filter in soapy water. Rinse and air dry. Replace the fil-

ter if needed.

10. Reverse the steps to reinstall all components.

90

MAINTENANCE

Breather Filter

Breather Filter/Hose

The breather filter is on the hose between the engine and air box.

1. Remove the left side panel.

See page 86.

2. Remove the hose clamps from

the filter and pull the filter out of
the hoses.

3. Inspect the filter for debris. Blow

gently through the filter in the
direction of the arrow to check
for clogging. Replace a damaged
or clogged filter.

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

Replace as needed.

5. Reinstall the filter and hose clamps. The filter is effective with the

arrow pointing in either direction.

NOTICE: Operation of your vehicle without a breather filter can cause engine

damage.

91

MAINTENANCE

7.6 m

5 cm

X

X

Screw

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward.

1. Position the vehicle on a level

surface. The headlight should be
approximately 7.6 m from a
wall.

2. Place the transmission in PARK.

3. Measure the distance from the floor to the center of the headlight

and make a mark on the wall at the same height. Include rider
weight on the seat when measuring.

4. Start the engine.Turn the head-

light switch to high beam.

5. Observe the headlight aim on the

wall. The most intense part of
the headlight beam should be 5
cm below the mark on the wall.

6. Tighten or loosen the lower

headlight screws to adjust the
beam upward or downward or to
the left or right.

92

MAINTENANCE

Position Light

Collar

Socket

Headlamp

Lights

Poor lighting can result in loss of control or an accident. Lights become dirty
during normal operation. Wash the headlights and taillights frequently.

Hot components can cause serious burns to skin. Do not service the headlamps
until they've cooled.

Headlight/Position Light Lamp Replacement

When servicing a halogen lamp, do
not touch the lamp with bare fingers.
Oil from your skin leaves a residue,
causing a hot spot that will shorten
the life of the lamp. Hold the plastic
part of the lamp.

1. Place the transmission in PARK.

2. Open the front rack cover.

3. Remove the plug at the back of the

headlight.

4. Pull the harness plug to disconnect

it from the back of the headlight.

5. Position light: Rotate the socket to

remove it. Go to step 6.
Headlamp: Reach under the
bumper and remove the rubber
cover from the back of the
headlight. Turn the collar counter­clockwise and carefully remove
the collar and socket.

6. Remove the lamp. Apply dielectric

grease to the socket and install a
new lamp.

7. Reverse all steps to reassemble the

headlight.

93

MAINTENANCE

Screws

Lights

Taillight/Brake Light Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the taillight socket counter-

clockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp

for proper operation.

6. Reinstall all components in reverse order.

Front Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Remove the lens attachment

screws.

3. Rotate the lamp to remove it.

4. Install the new lamp.

5. Reinstall the lens.

Rear Turn Signal Lamp Replacement

1. Place the transmission in PARK.

2. Rotate the turn signal socket counter-

clockwise to remove it.

3. Remove the lamp.

4. Apply dielectric grease to the socket.

5. Install the new lamp. Test the lamp

for proper operation.

6. Reinstall all components in reverse order.

94

Fuse Replacement

Fuse Panel

Fuses

5or61520 20

Fuse Feature Supported

5A Speedometer

15A Electronic Fuel Injection

20A (Main Fuse) Ignition, Lighting

20A Accessories, 12V Power Receptacle

If the engine stops or will not start, or
if you experience other electrical fail­ures, a fuse may need replacement.
Spare fuses are provided in a compart­ment on the top of the access door.

1. Open the front box cover.

2. Open the access door.

3. Remove the suspect fuse from the

fuse panel. Install a new fuse with
the same amperage.

4. Secure the access door.

5. Secure the box cover.

MAINTENANCE

95

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 116 for the recom­mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.

Plug Condition Torque Specification

New Spark Plug 12-15 N-m

Previously Installed Spark Plug 23-27 N-m

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plug for correct color.

Normal Spark Plug

The normal insulator tip is tan or brown. There will be few combustion
deposits. The electrodes are not burned or eroded. This indicates the
proper type and heat range for the engine and the service.

The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect throttle body
adjustments.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil con­sumption, use of non-recommended oil or incorrect throttle body adjust­ments.

96

Spark Plugs

Spark Plug Removal

1. Remove the left side panel.

See page 86.

2. Remove the spark plug cap.

3. Use the spark plug wrench

to remove the spark plug.
Turn the plug
counterclockwise to
remove it.

4. Inspect the electrodes for

wear and carbon buildup.
Replace worn or fouled
plugs. Verify that the gap is
at specification before
installation.

MAINTENANCE

5. Reinstall the spark plug.

Torque to specification. See
page 96.

6. Reinstall the spark plug cap.

97

MAINTENANCE

Vehicle Immersion

If your vehicle has been totally submerged in water and it's impossible
to have it serviced before further operation, perform the following pro­cedure.

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

1. Move the vehicle out of the water.

2. Remove the spark plug.

3. Drain any water found in the air box.

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

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