Polaris SPORTSMAN ACE 2014, SPORTSMAN ACE, SPORTSMAN ACE 570 Owner's Manual

Failure to heed the warnings and safety precautions

contained in this manual can result in severe injury or death.

Read this manual carefully.

™

SPORTSMAN ACE

Owner's Manual

for Maintenance and Safety

WARNING

Read, understand, and follow all of the instructions and safety precautions in
this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER Operate:

• If you are under age 16 and without a valid driver’s license.

• Without first viewing safety video and taking a ROHVA training course at
www.rohva.org.

• On excessively steep hills.

• On public roads (unless designated for off-road use).

• On paved surfaces - pavement may seriously affect handling and control.

• With non-Polaris approved accessories - they may seriously affect stability.

ALWAYS:

• Wear your seat belt. Vehicle rollover can cause severe injury or death.

• Secure cab nets or doors and keep hands and feet inside vehicle at all times.

• Wear a helmet, eye protection, gloves, long-sleeve shirt, long pants and
over-the-ankle boots.

• Avoid sharp turns or turns while applying heavy throttle.

• Operate slowly in reverse - avoid sharp turns or sudden braking.

RIDER MUST WEAR AN APPROVED HELMET AND PROTECTIVE GEAR.

RIDER MUST WEAR SEAT BELT.

NEVER USE ON PUBLIC ROADS.

NEVER USE WITH DRUGS OR ALCOHOL.

READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polaris.com
Polaris Sales Inc.
2100 Hwy. 55
Medina, MN 55340
Phone [phone]
Part No. 9924083 Rev 01
Printed in USA

1

WELCOME

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

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® electric vehicles
We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design and development of
your POLARIS vehicle.

For safe and enjoyable operation of your vehicle, be sure to follow the
instructions and recommendations in this owner’s manual. Review the
safety DVD that came with your vehicle. POLARIS also recommends
that all drivers take the ROHVA safety e-course and a ROHVA hands-on
safety training course. Visit www.rohva.org or call 866-267-2751.

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.

2

POLARIS® and SPORTSMAN ACE™ are trademarks of POLARIS Industries Inc.
Copyright 2013 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.

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

Printed in U.S.A.
2014 SPORTSMAN ACE Owner’s Manual
P/N 9924083

3

TABLE OF CONTENTS

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

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

Features and Controls. . . . . . . . . . . . . . . . . . . 24

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Emission Control Systems . . . . . . . . . . . . . . . 78

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 128

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 130

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 131

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 142

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

4

INTRODUCTION

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

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 ha zard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.

WARNING

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

CAUTION

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

NOTICE

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

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

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

5

INTRODUCTION

Failure to heed the warnings and safety precautions contained in this manual
can result in severe injury or death. Your POLARIS vehicle is not a toy and can
be hazardous to operate. This vehicle handles differently than cars, trucks or
other off-road vehicles. 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 and review the safety DVD that came with your
vehicle. A free extra copy of the DVD can be obtained by contacting your local
POLARIS dealer. Understand all safety warnings, precautions and operating
procedures before operating the vehicle. Keep this manual with the vehicle.

• Never operate this vehicle without proper instruction. Take an authorized
training course. Visit www.rohva.org or call 866-267-2751.

• This vehicle is an ADULT VEHICLE ONLY. You MUST be at least age 16 and
have a valid driver’s license to operate this vehicle.

• Always use the cab nets (or doors) while riding in this vehicle. Always keep
hands, feet and all other body parts inside the vehicle at all times.

• Always wear a helmet, eye protection, gloves, long-sleeve shirt, long pants
and over-the-ankle boots.

• Never use this vehicle with drugs or alcohol, as these conditions impair
judgment and reduce operator reaction time.

• Complete the New Operator Driving Procedures outlined on pages 54-55.
Never allow a guest to operate this vehicle until the guest has completed the
New Operator Driving Procedures.

• Never permit a guest to operate this vehicle unless the guest has reviewed the
owner’s manual and all safety labels and has comple ted a safety training
course.

European Vibration and Noise

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

The operating conditions of the machinery during testing:
The vehicles were in like-new condition. The environmen t was controlled as

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

factors, including:

• Instrument and calibration uncertainty

• Varia tions in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

WARNING

6

INTRODUCTION

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: ___________________________________________________

Vehicle Identification Number (VIN): _________________________________________

Engine Serial Number: ______________________________________________ _____

Key Number____________________________________________________________

Engine Serial

Number

Key

Number

VIN

(Right Front Frame)

####

7

SAFETY

Safety Training

Safety training is a top priority for POLARIS. POLARIS strongly
encourages you and any family members who will be riding this vehicle
to take a training course.

ROHVA (Recreational Off-Highway Vehicle Association) provides both
an online safety e-course and a hands-on safety course. Visit
www.rohva.org or call 866-267-2751.

Your POLARIS vehicle is considered 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 recreational off-road vehicle safety in
the United States, visit www.rohva.org, call 866-267-2751 or call
POLARIS at 800-342-3764.

8

SAFETY

Safe Riding Gear

Always wear helmet, eye protection, gloves, long-sleeve shirt, long
pants, over-the-ankle boots and seat belt at all times. Protective gear
reduces the chance of injury.

Helmet

W e aring a helmet can prevent a severe head injury. Whenever riding this
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of
Transportati on (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.

Helmet

Eye

Protection

Gloves

Over-the-Ankle

Boots

Long

Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding this 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

Wear gloves for comfort and for protection from sun, cold weather and
other elements.

Boots

Wear sturdy over-the-ankle boots for support and protection. Never ride
a POLARIS vehicle with bare feet or sandals.

Clothing

Wear long sleeves and long pants to protect arms and legs.

Rider Comfort

Under certain operating conditions, heat generated by the engine and
exhaust system can elevate temperatures in the rider cab area. The
condition occurs most frequently when a vehicle is being operated in
high ambient temperatures at low speeds and/or high load conditions for
an extended period of time. The use of certain windshield, roof and/or
cab systems may contribute to this condition by restricting airflow . Any
discomfort due to heat buildup in this area can be minimized by wearing
proper riding apparel and by varying speeds to increase airflow.

10

SAFETY

Safety Labels and Locations

Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions of the labels on the vehicle carefully. If
any of the labels depicted 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.

General Warning

11

SAFETY

Safety Labels and Locations

General Warning

WARNING
Require Proper Use of Your Vehicle

Do your part to prevent injuries:

• Do not allow careless or reckless driving.

• Make sure operators are 16 or older with a valid
driver’s license.

• Do not let people drive after using alcohol or drugs.

• Do not allow operation on public roads (unless
designated for off-highway vehicle access) - collisions with cars and trucks can
occur.

• Do not exceed seating capacity: 1 occupant.

Improper vehicle use can result in SEVERE INJURY or DEATH

Be Prepared

• Fasten seat belt.

• Wear an approved helmet and protective gear.

• ALWAYS use vehicle cab nets and/or doors.

• Driver must be able to sit with back against seat, feet flat on
the floor, and hands on steering wheel. Stay completely
inside the vehicle.

Drive Responsibly

Avoid loss of control and rollovers:

• Avoid abrupt maneuvers, sideways sliding,
skidding or fishtailing, and never do donuts.

• Slow down before entering a turn.

• Avoid hard acceleration when turning, even
from a stop.

• Plan for hills, rough terrain, ruts and other
changes in traction and terrain.

• Avoid paved surfaces.

• Avoid sidehilling (riding across slopes).

Be Sure to Pay Attention and Plan Ahead

If you think or feel the vehicle may tip or roll, reduce your risk of injury:

• Keep a firm grip on the steering wheel and brace yourself.

• Do not put any part of your body outside of the vehicle for any reason.

LOCATE AND READ OWNER’S MANUAL. FOLLOW ALL INSTRUCTIONS
AND WARNINGS. ALWAYS REVIEW SAFETY VIDEO AND TAKE ROHVA
TRAINING (rohva.org).

7180534

Rollovers have caused

severe injuries and death,

even on flat, open areas.

12

SAFETY

Safety Labels and Locations

Load/Passenger/Tire Pressure Warning

WARNING

• Never carry passengers in cargo box.

• Passengers can be thrown off. This can
cause serious injury or death.

WARNING

IMPROPER TIRE PRESSURE OR
OVERLOADING CAN CAUSE LOSS OF
CONTROL RESULTING IN SERIOUS
INJURY OR DEATH.

• Reduce speed and allow greater distance

for braking when carrying cargo.

• Overloading or carrying tall, off-center, or

unsecured loads will increase your risk of
losing control. Loads should be centered
and carried as low as possible in box.

• For stability on rough or hilly terrain,

reduce speed and cargo.

7180636

SPORTSMAN ACE

MAXIMUM CARGO BOX LOAD 240 lbs.

(108 kg)

TIRE PRESSURE IN PSI (KPa) FRONT 7 (48)

REAR 7 (48)

MAXIMUM WEIGHT CAPACITY

INCLUDES WEIGHT OF OPERATOR, CARGO AND
ACCESSORIES

575 lbs.

(260 kg)

Read Operation and Maintenance Manual for more detailed loading information.

Load/Passenger/Tire

Pressure Warning

13

SAFETY

Safety Labels and Locations

PVT System Warning

WARNING

Improper service or maintenance of
this PVT system can result in vehicle
damage, SEVERE INJURY or
DEATH.

Always look for and remove debris
inside and around clutch and vent
system when replacing belt.

Read owner's manual or see
authorized Polaris dealer.

7177469

Hitch Capacity Label

TRAILER MAX WEIGHT: 1500 LBS. (682 KG) ON LEVEL GROUND
850 LBS. (386 KG) UP TO 15 DEGREES
HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

7170509

PVT System Warning

14

SAFETY

Safety Warnings

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

Operating Without Instruction

Operating this vehicle without proper instruction
increases the risk of an accident. The operator
must understand how to operate the vehicle
properly in different situations and on different
types of terrain. Complete the New Operator
Driving Procedures outlined on pages 54-55.

All operators must read and understand the
owner's manual and all warning and instruction
labels before operating the vehicle. Never allow a
guest to operate this vehicle until the guest has
completed the New Operator Driving Procedures
outlined on pages 54-55.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY.
Operation is prohibited for anyon e under 16 years
of age or anyone without a valid driver ’s license.

The operator must be tall enough to sit with back
against the seat, both feet flat on the floor and
both hands on the steering wheel.

Using Alcohol or Drugs

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

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

WARNING

15

SAFETY

Safety Warnings

Failure to Inspect Before Operating

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

Always perform the pre-ride inspection
before each use of your vehicle to make
sure it's in safe operating condition. See
page 48.

Always follow the inspection and
maintenance procedures and schedules
described in this owner’s manual. See
page 79.

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.

Always wear a helmet, eye protection,
gloves, long-sleeve shirt, long pants and
over-the-ankle boots.

Seat Belts

Riding in this vehicle without wearing the seat belt increases the risk of serious
injury in the event of rollover, loss of control, other accident or sudden stop. Seat
belts may reduce the severity of injury in these circumstances.

The operator MUST wear the seat belt at all times.

Cab Nets

Riding in this vehicle without using the cab nets (or doors, if equipped) increases
the risk of serious injury or death in the event of an accident or rollover. Always
use the cab nets (or doors) while riding in this vehicle. Always keep hands and

feet inside the vehicle at all times.

16

SAFETY

Safety Warnings

Carrying a Passenger

This POLARIS vehicle is a single-rider
vehicle. Carrying a passenger greatly
reduces the operator's ability to control
the vehicle, which may result in an
accident or rollover. Carrying a
passenger in the cargo box could result
in a fall from the vehicle or contact with
moving components. Never carry a
passenger on this vehicle.

Operating With a Load on the Vehicle

The weight of both cargo and operator impacts vehicle operation and stability.
For your safety and the safety of others, carefully consider how your vehicle is
loaded and how to safely operate the vehicle. Follow the instructions in this
manual for loading, tire pressure, gear selection and speed.

• Do not exceed vehicle weight capacities. The vehicle’s maximum weight
capacity is listed in the specifications section of this manual and on a label on
the vehicle. When determining the weight you are adding to the vehicle,
include the weight of the operator, accessories, loads in the rack or box and
the load on the trailer tongue. The combined weight of these items must not
exceed the maximum weight capacity.

• The recommended tire pressures are listed in the specifications section of this
manual and on a label on the vehicle.

Always follow these guidelines:

Under ANY of these conditions: Do ALL of these steps:

Operator and/or cargo exceeds half the
maximum weight capacity

1. Slow down.

2. Verify tire pressure.

3. Use extra caution when
operating.

Operating in rough terrain
Operating over obstacles
Climbing an incline
Towing

17

SAFETY

Safety Warnings

Improper Tire Maintenance

Operating this vehicle 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 vehicle.

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

Operating on Pavement

This vehicle's tires are designed for off-road
use only, not for use on pavement. Operating
this vehicle on paved surfaces (including
sidewalks, paths, parking lots and driveways)
may adversely affect the handling of the
vehicle and may increase the risk of loss of
control and accident or rollover. Avoid
operating the vehicle on pavement. If it's
unavoidable, travel slowly, travel short
distances and avoid sudden turns or stops.

Operating on Public Roads

Operating this vehicle on public streets,
roads or highways could result in a collision
with another vehicle. Never operate this
vehicle on any public street, road or highway,
including dirt and gravel roads (unless
designated for off-highway use). In some
areas it's unlawful to operate this vehicle on
public streets, roads and highways.

Operating at Excessive Speeds

Operating this vehicle at excessive speeds
increases the operator's risk of losing
control. Always operate at a speed that's
appropriate for the terrain, the visibility and
operating conditions and your skills and
experience.

18

SAFETY

Safety Warnings

Turning Improperly

Turning improperly could cause loss of traction, loss of control, accident or
rollover. Always follow proper procedures for turning as described in this
owner’s manual.

Avoid sharp turns. Never turn while applying heavy throttle. Never make abrupt
steering maneuvers. Practice turning at slow speeds before attempting to turn at
faster speeds.

Jumps and Stunts

Exhibition driving increases the risk of an
accident or rollover. DO NOT do power slides,
“donuts”, jumps or other driving stunts. Avoid
exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of
control or rollover. Use extreme caution when
operating on hills. Always follow proper
procedures for hill climbing as described in this
owner's manual. See page 58.

Descending Hills Improperly

Improperly descending a hill could cause loss
of control or rollover. Always follow proper
procedures for traveling down hills as
described in this owner’s manual. See page

60.

19

SAFETY

Safety Warnings

Crossing Hillsides

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

If crossing a hillside is unavoidable, always
follow proper procedures as described in this
owner's manual. See page 59.

Stalling While Climbing a Hill

St alling or rolling backwards while climbing a
hill could cause a rollover. Maintain a steady
speed when climbing a hill.

If you lose all forward speed:

Apply the brakes gradually until the vehicle
is fully stopped. Place the transmission in
reverse and slowly allow the vehicle to roll
straight downhill while applying light brake
pressure to control speed.

Operating in Unfamiliar Terrain

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

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

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

20

SAFETY

Safety Warnings

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 63.

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

Improper Tire Maintenance

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

Always use the size and type of tires specified for your vehicle. Always maintain
proper tire pressure as described in this owner's manual and on safety labels.

Skidding or Sliding

Failure to use extra caution when operating on
excessively rough, slippery or loose terrain
could cause loss of traction, loss of control,
accident or rollover. Do not operate on
excessively slippery surfaces. Always slow
down and use additional caution when
operating on slippery surfaces.

Skidding or sliding due to loss of traction can
cause loss of control or rollover (if tires regain
traction unexpectedly). Always follow proper
procedures for operating on slippery surfaces
as described in this owner's manual. See page 57.

Operating Over Obstacles

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

Before operating in a new area, check
for obstacles. Avoid operating over
large obstacles such as large rocks and
fallen trees. Always follow the proper
procedures outlined in this manual
when operating over obstacles. See
page 62.

21

SAFETY

Safety Warnings

Operating Through Water

Operating through deep or fast-flowing
water can cause loss of traction, loss of
control, rollover or accident. Never operate
in fast-flowing water or in water that
exceeds the floor level of the vehicle.

Always follow proper procedures for
operating in water as described in this
owner’s manual. See page 61.

Wet brakes may have reduced stopping
ability . After leaving water , test the brakes. Apply them lightly several times while
driving slowly. The friction will help dry out the pads.

Operating on Frozen Bodies of Water

Severe injury or death can result if the
vehicle and/or the operator fall through the
ice. Never operate the vehicle on a frozen
body of water unless you have first verified
that the ice is sufficiently thick to support
the weight and moving force of the vehicle,
you and your cargo, together with any
other vehicles in your party.

Always check with local authorities and
residents to confirm ice conditions and
thickness over your entire route. Vehicle
operators assume all risk associated with
ice conditions on frozen bodies of water.

Operating a Damaged Vehicle

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

22

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Always follow the instructions in this owner’s manual for carrying cargo. See
page 64.

• Never exceed the stated load capacity for this vehicle. See page 12.

• Cargo should be properly distributed and securely attached. See page 64.

• Reduce speed when carrying cargo or pulling a trailer. Allow a greater distance
for braking.

Poor Visibility

Operating this vehicle in darkness or inclement weather could result in a
collision or accident, especially if operating on a road or street. This vehicle 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.

Refueling

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always turn off the engine when refueling.

• Always refuel outdoors or in a well ventilated area free of any source of flame
or sparks.

• Always use an approved gasoline container to store fuel and remove the
container from the vehicle before filling to avoid fuel ignition due to electrical
static discharge.

• 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.

23

SAFETY

Safety Warnings

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

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, to
avoid debris build-up around the exhaust system.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle by
someone under the age of 16, without a drivers license, or without proper
training. This could result in an accident or rollover. Always remove the ignition
key when the vehicle is not in use.

Equipment Modifications

Your POLARIS vehicle is designed to provide safe operation when used as
directed. Modifications to your vehicle may negatively impact vehicle stability.
Failure of critical machine components may result from operation with any
modifications, especially those that increase speed or power. This vehicle may
become less stable at speeds higher than those for which it is designed. Loss of
control may occur at higher speeds.

Do not install any non-POLARIS-approved accessory or modify the vehicle for
the purpose of increasing speed or power. Any modifications or installation of
non-POLARIS-approved accessories could create a substantial safety hazard
and increase the risk of bodily injury.

The warranty on your POLARIS vehicle will be terminated if any non-POLARIS­approved equipment and/or modifications have been added to the vehicle that
increase 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.

FOR MORE INFORMATION ABOUT SAFETY

call POLARIS at 1-800-342-3764.

24

FEATURES AND CONTROLS

Component Locations

Hip

Bars

Cargo

Box

Shifter

Cab Nets

Steering

Wheel

Throttle

Pedal

Brake
Pedal

ROPS
Frame

Front Box

Cover

Headlights

Taillights

Engine

Intake

Pre-Filter

Radiator

Single-Rider

Seat

Brush Guard

Fuel Cap

25

FEATURES AND CONTROLS

Trailer Receiver Hitch Bracket

This vehicle is equipped with a
receiver hitch bracket for a trailer
hitch. Trailer towing equipment is not
supplied with this vehicle.

To avoid injury and property damage,
always heed the warnings and towing
capacities outlined on pages 64-66.

Service Access Panels

Access serviceable engine
components through the engine access
panel behind the seat. Remove the seat
and release the access panel latches to
remove the access panel.

Remove rear access panel to access the
air box and spark plug. The rear access
panel is located in the bed of the cargo
box. Pull the rear edge of the access
panel upward to remove it.

Radiator Access/Bumper Removal

The front bumper can be
removed to clean debris from
the radiator.

1. Remove the four (4) torx
screws and six (6) plastic
rivets.

2. Lift the front bumper to

remove it from the vehicle.

Receiver Hitch

Rear Access Panel

Screws

Rivets

26

FEATURES AND CONTROLS

Steering Wheel

The steering wheel can be tilted upward or
downward for rider preference.

Lift and hold the steering wheel adjustment
lever while moving the steering wheel
upward or downward. Release the lever when
the steering wheel is at the desired position.

Always make sure the steering wheel
position does not impede proper operation of
the brake pedal, throttle pedal and all other
controls.

Front Box Cover

Remove the front box cover
and access panel to access the
radiator cap, coolant overflow
bottle and brake master
cylinder reservoir.

1. Turn the box cover
fasteners 1/4 turn.

2. Lift the rear edge of the box

cover.

3. Using the pliers provided in

the tool kit, remove the two
(2) push darts from the
access panel. Remove the
panel.

Adjustment

Lever

Cover Fasteners

Access Panel

27

FEATURES AND CONTROLS

Cab Nets

Riding in this vehicle without
using the cab nets (or doors, if
equipped) increases the risk of
serious injury or death in the event
of an accident or rollover. Cab
nets (or doors) must be used at all
times. Make sure all latches on
both sides of the vehicle are secure
before operating the vehicle.

Always inspect cab nets and
latches for tightness, wear and
damage before each use of the
vehicle. Use the strap adjusters to
tighten any loose straps. Promptly
replace worn or damaged cab nets
and latches with new cab nets and
latches. Please see your authorized
POLARIS dealer.

Cab Net Latches

28

FEATURES AND CONTROLS

Fuel Cap

The fuel tank filler cap is located
on the right side of the vehicle
near the seat. When refueling,
always use either leaded or
unleaded gasoline with a
minimum pump octane number
of 87 R+M/2 octane. Do not use

fuel with ethanol content greater
than 10 percent, such as E-85
fuel.

Seat

Seat Adjustments

Always make sure the seat position allows for proper access and
operation of the brake pedal, throttle pedal and all other controls.

The seat release lever is located at the left side of the seat. Push the
release lever downward and slide the seat forward or rearward to the
desired position. Release the lever. The seat will lock into the new
position.

Seat Removal

1. Push the seat release lever
downward and slide the seat
forward until it slides off the
frame.

2. Lift the seat away from the

vehicle.

3. Reverse the procedure to reinstall

the seat.

Fuel Cap

Seat Release

Lever

29

FEATURES AND CONTROLS

Seat Belt

This POLARIS vehicle is equipped with three-point lap and diagonal
seat belts. Always secure the seat belt before riding.

To wear the seat belt properly, follow this procedure:

1. Pull the seat belt latch downward and across your chest toward the
buckle at the inner edge of the seat. The belt should fit snugly across
your hips and diagonally across your chest. Make sure the belt is not
twisted.

2. Push the latch plate into the buckle until it clicks.

3. Release the strap, it will self-tighten.

4. Press the red release latch on the buckle to release the seat belt.

Seat Belt Inspection

Inspect all seat belts for proper operation before each use of the vehicle.

1. Push the latch plate into the buckle until it clicks. The latch plate
must slide smoothly into the buckle. A click indicates that it's
securely latched.

2. Push the red release latch in the middle of the buckle to make sure it

releases freely.

3. Pull each seat belt completely out and inspect the full length for any

damage, including cuts, wear, fraying or stiffness. If any damage is
found, or if the seat belt does not operate properly , have the seat belt
system checked and/or replaced by an authorized POLARIS dealer.

4. To clean dirt or debris from the

seat belts, sponge the straps
with mild soap and water. Do
not use bleach, dye or
household detergents.Use a
garden hose to flush out the
retractor and latch housing
regularly.

Retractor

Housing

Latch

Housing

30

FEATURES AND CONTROLS

Switches

AWD Switch

12V Accessory

Outlet

Ignition Switch/Light Switch

Instrument Cluster

31

FEATURES AND CONTROLS

Switches

Ignition Switch/Light Switch

Use the ignition switch to start the engine
and to turn the lights on or off. The key
can be removed from the switch when it is
in the OFF position.

All Wheel Drive (AWD) Switch (if equipped)

The AWD Switch has two positions:

• All Wheel Drive (AWD)

• Two Wheel Drive (2WD).

Press the top of the rocker switch to engage All
Wheel Drive. Press the bottom of the switch to
operate in two wheel drive.

See page 35 for AWD operating instructions.

Auxiliary Outlet

The vehicle is equipped with a 12-volt accessory outlet on the dash. Use
the outlet to power an auxiliary light or other optional accessories or
lights. For service, the dash outlet connection is under the dash.

OFF Turn the key to the OFF

position to stop the engine.
Electrical circuits are off.

LIGHTS ON The lights are on. Electrical

circuits are on. Electrical
equipment can be used.

LIGHTS OFF The lights are off. Electrical

circuits are on. Electrical
equipment can be used.

START Turn the key to the START

position to engage the
electric starter. See page 52
for starting procedures.

OFF START

AWD

2WD

32

FEATURES AND CONTROLS

Gear Selector

To change gears, stop the
vehicle, and with the
engine idling, move the
lever to the desired gear.
Do not attempt to shift
gears with engine speed
above idle or while the
vehicle is moving.

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

H: High Gear

NOTICE: Do not attempt to shift the transmission while the vehicle is moving or

damage to the transmission could result. Always shift when the
vehicle is stationary and the engine is at idle.

Using Low Range

Always shift into low gear for any of the following conditions.

• Operating in rough terrain or over obstacles

• Loading the vehicle onto a trailer

• Towing heavy loads

Gear Selector

33

FEATURES AND CONTROLS

Brake Pedal

Depress the brake pedal to slow or
stop the vehicle. Apply the brakes
while starting the engine.

Throttle Pedal

Push the pedal down to increase
engine speed. Spring pressure returns
the pedal to the rest position when
released. Always check that the
throttle pedal returns normally before
starting the engine. Make sure there's
adequate throttle pedal freeplay. See
page 106 for throttle pedal adjustment
procedures.

This vehicle is equipped with a throttle release switch, 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 pedal, engine speed will be limited, and power to the rear wheels
will be reduced.

Throttle

Pedal

Brake
Pedal

34

FEATURES AND CONTROLS

Rollover Protective Structure (ROPS)

The Rollover Protective Structure
(ROPS) on this vehicle meets
OSHA 1928.53 rollover
performance requirements. Always
have your authorized POLARIS
dealer thoroughly inspect the ROPS
if it ever becomes damaged in any
way.

No device can assure occupant
protection in the event of a rollover.

When used with seat belts and cab
nets, the ROPS helps prevent
occupants from being ejected from
the vehicle. Always follow all safe
operating practices outlined in this
manual to avoid vehicle rollover.

WARNING! Vehicle rollover could
cause severe injury or death. Always
avoid operating in a manner that could
result in vehicle rollover.

ROPS Label

(on ROPS behind rear cab)

35

FEATURES AND CONTROLS

All Wheel Drive (AWD) System

The All Wheel Drive system is controlled by the
AWD switch. When the switch is on 2WD (2X4),
the vehicle is in two-wheel drive at all times.
When the switch is on AWD (4x4), the vehicle is
in all wheel drive and the 4X4 indicator in the
instrument cluster will be on.

When in AWD, the demand drive unit will
automatically engage any time the rear wheels lose
traction. When the rear wheels regain traction, the
demand drive unit will automatically disengage.

There is no limit to the length of time the vehicle may remain in AWD.

Engaging AWD

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

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

NOTICE: Switching to AWD while the rear wheels are spinning or slipping may

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

AWD

2WD

36

FEATURES AND CONTROLS

Instrument Cluster

High water pressure may damage
components. Wa sh the vehicle by
hand or with a garden hose using
mild soap. Do not use alcohol to
clean the instrument cluster. Do
not allow insect sprays to contact
the lens.

Speedometer

The speedometer displays vehicle
speed in either miles per hour
(MPH) or kilometers per hour
(km/h). See page 40.

Mode Button

Use the MODE button to toggle
through mode options. See page 40
for operation of the modes.

Rider Information

Center

Speedometer

Indicator

Lamps

MODE

Button

37

FEATURES AND CONTROLS

Instrument Cluster

Indicator Lamps

Lamp Indicates Condition

Vehicle
Speed

When standard mode is selected, speed displays in
miles per hour.

When metric mode is selected, speed displays in
kilometers per hour.

Over
Temperature

This lamp illuminates to indicate an overheated
engine. If the indicator flashes, the overheating
condition remains, and the system will automatically
reduce engine power.

Neutral This lamp illuminates when the transmission is in

neutral and the ignition key is in the ON position.

High Beam (if
equipped)

This lamp illuminates when the headlamp switch is
set to high beam.

Helmet/Seat
Belt

This lamp flashes for several seconds when the key is
turned to the ON position. The lamp is a reminder to
wear helmet and seat belt before operating.

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

Do not operate the vehicle if this warning appears.
Serious engine damage could result. See your dealer.

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

The information center is set to display standard units of measurement
and a 12-hour clock at the factory. To change to metric and/or a 24-hour
clock, see page 41.

1. Gear Indicator - This indicator displays gear shifter position.

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

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

Trip 1

km

mi

RPM

FE

88

:

88

1

2

6

5

4

7

3

8

39

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

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

in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your POLARIS dealer.

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

meter, engine hour meter and programmable service hour interval.

4. Under / Over Voltage - This warning usually indicates that the

vehicle 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.

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

page 41 for resetting instructions.

6. Service Indicator - A flashing wrench symbol alerts the operator

that the preset service interval has been reached. The vehicle should
be brought to your POLARIS dealer for scheduled maintenance.
See page 41 for resetting instructions.

7. 4X4 Indicator - This indicator illuminates when the 4X4 system is

engaged (switch is on 4X4).

8. Turf Mode Indicator (if equipped) - This indicator illuminates

when the operator unlocks the differential.

40

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Use the MODE button to toggle through the
information area options.

Display Units (Standard/Metric)

The display can be changed to show either
standard or metric units of measurement for
each of the following settings.

Tip: To exit the set-up mode, turn the key off. Wait 5 seconds, then turn the key

on. The gauge display the mode that was displayed prior to setting the
units.

1. Turn the key to the OFF position.

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

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

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

5. Repeat the procedure to change remaining display settings.

Standard Display Metric Display

Distance Miles Kilometers
Fuel U.S. Gallons Liters, Imperial Gallons
Temperature Fahrenheit Celsius
Time 12-Hour Clock 24-Hour Clock

MODE

Button

41

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Clock Mode

Tip: The clock must be reset any time the battery has been disconnected or

discharged.

1. Turn the key to the ON position. Use the MODE button to toggle to
the odometer display.

2. Press and hold the MODE button until the hour segment flashes.
Release the button.

3. With the segment flashing, tap the MODE button to advance to the
desired setting.

4. Press and hold the MODE button until the next segment flashes.
Release the button.

5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new
settings and exit the clock mode.

6. Turn the key to the OFF position.

Odometer Mode

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

Trip Meter Mode

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

Hour Meter Mode

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

Engine Temperature Mode

This mode displays current temperature of the coolant.

Tachometer Mode

The engine RPM is displayed digitally.

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

changes in humidity, temperature and elevation.

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Programmable Service Interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. The service interval is
programmed at 50 hours at the factory. Use the following procedure to
change the service interval.

1. Press the MODE button until remaining service hours display.

2. Press and hold the MODE button.

3. When the service hours flash, press and release the MODE button to
advance the hours to the desired setting (including OFF). Press and
hold the MODE button to set the new service hour interval.

Diagnostic Display Mode

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

The diagnostic mode is accessible only when the check engine warning
indicator activates after the key has been turned on. Leave the key on if
you want to view the active code (failure code).

The diagnostic mode becomes inaccessible if the key is turned off and
on and the warning indicator is no longer active. This allows the
determination of persistent as well as intermittent faults.

Inactive codes are stored in the history of the unit.

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Engine Error Codes

The error screen displays
only when the CHECK
ENGINE light is on or
when it goes on and off
during one ignition cycle.
Error codes are not stored.
When the key is turned
OFF, the code and
message is lost, but will
reappear if the fault
reoccurs after restarting
the engine.

If the CHECK ENGINE
light illuminates, retrieve
the error codes from the
display.

1. If the error codes are not displayed, use the MODE button to toggle
until “Ck ENG” displays on the main line of the display.

2. Press and hold the MODE button to enter the diagnostics code
menu.

3. Record the three numbers displayed in the gear position, clock and
odometer displays.

4. Press the MODE button to advance to the next error code.

5. Press and hold the MODE button to exit the diagnostics code menu.

6. See pages 44-45 for code definitions and failure descriptions. Please

see your POLARIS dealer for all major repairs.

Suspect Parameter

Number (SPN)

Error Code

Number (0-9)

Failure Mode Indicator (FMI)

44

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

Open Load: There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground

: The wire is shorted to ground between the electronic

control unit and the item listed in the chart.

Shorted Load

: The wires leading to the item listed in the chart are

shorted together, or the item has shorted internally.

Short-to-Battery

: The wire leading from the item listed in the chart to

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

45

FEATURES AND CONTROLS

Instrument Cluster

Diagnostic Display Code Definitions

*Assumes unipolar configuration of stepper motor

Diagnostic Codes

Component Condition SPN FMI

Throttle Position Sensor

Voltage Too High 51 3
Voltage Too Low 51 4

Engine Temperature Sensor

Voltage Too High 110 3
Voltage Too Low 110 4
Temperature Too High 110 16
Engine Overheat Shutdown 110 0

Intake Air Temperature Sensor

Voltage Too High 105 3
Voltage Too Low 105 4

Manifold Absolute Pressure Sensor Voltage Too High 102 3

Voltage Too Low 102 4
Crankshaft Position Sensor Circuit Fault 636 8
Gear Sensor Signal Voltage Too Low (to Calibrate) 523 4

Voltage Too High 523 3

Signal Fault 523 2
Injector 1 (MAG) Driver Circuit Open/Grounded 651 5

Driver Circuit Short to B+ 651 3
Ignition Coil Primary Driver 1 (MAG) Driver Open/Grounded 1268 5

Driver Circuit Short to B+ 1268 3
Fuel Pump Driver Circuit

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 1347 3
Fan Relay Driver Circuit Driver Circuit Open/Grounded 1071 5

Driver Circuit Short to B+ 1071 3
Idle Air Control Driver Circuit Grounded 520193 5

Shorted Load* 520193 11
Starter Enable Circuit Driver Circuit Short to B+ 1321 3
All Wheel Drive Control Driver Circuit Short to B+ 520207 3
System Power Voltage Too High 168 3

Voltage Too low 168 4
Throttle Safety Signal Voltage Too High 520194 3

Voltage Too Low 520194 4

Signal Out of Range 520194 2

Throttle Stuck 520194 7
Active Descent Control System Driver Circuit Short to B+ 520203 3

46

OPERATION

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

Vehicle Break-in Period

The break-in period for your new POLARIS vehicle is the first 25 hours
of operation, or the time it takes to use the first two tanks full of
gasoline. No single action on your part is as important as a proper break­in period. Careful treatment of a new engine and drive components will
result in more efficient performance and longer life for these
components. Perform the following procedures carefully.

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.

Use of any oils other than those recommended by POLARIS may
cause serious engine damage. We recommend the use of POLARIS
PS-4 Full Synthetic 5W-50 4-Cycle Oil for your 4-cycle engine.

WARNING

47

OPERATION

Vehicle Break-in Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 28. Always exercise
extreme caution whenever handling gasoline.

2. Check the oil level. See page 87. Add the recommended oil as

needed to maintain the oil level in the safe operating range.

3. Complete the New Operator Driving Procedures outlined on pages

54-55.

4. Avoid aggressive use of the brakes.

5. Vary throttle positions. Do not operate at sustained idle.

6. Pull only light loads.

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

on the daily pre-ride inspection checklist. See page 48.

8. During the break-in period, change both the oil and the filter at 25

hours or one month.

9. Check fluid levels of transmission and all gearcases after the first 25

hours of operation and every 100 hours thereafter.

Brake System Break-in

Apply only moderate braking force for the first 50 stops. Aggressive or
overly forceful braking when the brake system is new could damage
brake pads and rotors.

PVT Break-in (Clutches/Belt)

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

If a belt fails, always clean any debris from the PVT intake and outlet
duct and from the clutch and engine compartments when replacing the
belt.

48

OPERATION

Pre-Ride Inspection

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

Item Remarks Page

Brake system/pedal travel Ensure proper operation 33

107
Brake fluid Ensure proper level 108
Front suspension Inspect, lubricate if necessary 84
Rear suspension Inspect, lubricate if necessary 84
Steering Ensure free operation 110
Tires Inspect condition and pressure 12

111
Wheels/fasteners Inspect, ensure fastener tightness 111
Frame nuts, bolts, fasteners Inspect, ensure tightness ­Fuel and oil Ensure proper levels 39

87

Coolant level Ensure proper level 98

97
Coolant hoses Inspect for leaks ­Throttle Ensure proper operation 105
Indicator lights/switches Ensure proper operation 31
Air filter, pre-filter Inspect, clean 102-

103
Intake pre-filters Inspect, clean 103
Headlamps Check operation, apply POLARIS

dielectric grease when lamp is
replaced

113

Brake light/tail lamps Check operation, apply POLARIS

dielectric grease when lamp is
replaced

115

Seat Latch Push down on the seat back to

ensure the latch is secure

28

Seat Belt Check length of belt for damage,

check latches for proper operation

29

Cab Nets Check for wear or damage, ensure

proper installation

27

49

OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the
operation of this vehicle in your area. Respect the environment in which
you ride your vehicle. 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 . Tread 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.

50

OPERATION

Safe Operation Practices

1. Visit the Recreational Off-Highway Vehicle Association web site
and take the free on-line training course. Complete the
recommended safety training before operating this vehicle. Visit
www.rohva.org or call 866-267-2751.

2. Do not allow anyone under 16 years of age or without a valid

driver’s license to operate this vehicle.

3. Never carry a passenger on this vehicle.

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

run in an enclosed area.

5. Never operate with accessories not approved by POLARIS for use

on this vehicle.

6. Operate this vehicle off-road only. Never operate this vehicle on any

public street, road or highway, including dirt and gravel roads
(unless designated for off-highway use).

7. 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.

8. Always operate at a speed that's appropriate for the terrain, the

visibility and operating conditions and your skills and experience.
Never operate at excessive speeds. Never attempt wheelies, jumps,
or other stunts. Keep both hands on the steering wheel during
operation.

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

vehicle.

51

OPERATION

Safe Operation Practices

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

11. Never operate a damaged vehicle. After any rollover or accident,
have a qualified service dealer inspect the entire machine for
possible damage.

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

13. Do not touch hot exhaust system components. Always keep
combustible materials away from the exhaust system.

14. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.

52

OPERATION

Starting the Engine

1. Position the vehicle on a level surface outdoors or in a well­ventilated area.

2. Sit in the driver's seat and fasten the seat belt. Secure the cab nets.

3. Place the transmission in PARK.

4. Apply the brakes. Do not press the throttle pedal while starting the

engine.

5. Turn the ignition key to the START

position. Engage the starter for a
maximum of five seconds. Release
the key when the engine starts. Turn
the key to either LIGHTS ON or
LIGHTS OFF.

6. If the engine does not start within

five seconds, return the ignition
switch to the OFF position and wait
five seconds. Repeat steps 5 and 6
until the engine starts.

7. Vary the engine RPM slightly with

the throttle to aid in warm up until the engine idles smoothly.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

Cold Weather Operation

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

OFF START

53

OPERATION

Stopping the Engine

1. Release the throttle pedal completely and brake to a complete stop.

2. Place the transmission in PARK.

3. Turn the engine off.

Braking

1. Release the throttle pedal completely. (When the throttle pedal is
released completely and engine speed slows to near idle, the vehicle
has no engine braking.)

2. Press on the brake pedal evenly and firmly. Practice starting and

stopping (using the brakes) until you're familiar with the controls.

Parking the Vehicle

1. Stop the vehicle on a level surface. When parking inside a garage or
other structure, be sure that the structure is well ventilated and that
the vehicle is not close to any source of flame or sparks, including
any appliance with pilot lights.

2. Place the transmission in PARK.

3. Turn the engine off.

4. Remove the ignition key to prevent unauthorized use.

54

OPERATION

New Operator Driving Procedures

1. Read and understand the owner's manual and all warning and
instruction labels before operating this vehicle.

2. Visit the Recreational Off-Highway Vehicle Association web site

and take the free on-line training course. Visit www.rohva.org or
call 866-267-2751. Hands-on training is also available through
ROHVA.

3. Perform the pre-ride inspection. See page 48.

4. Do not tow or carry cargo during this period.

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

vehicle operation and handling.

6. The driver must wear helmet, eye protection, gloves, long-sleeve

shirt, long pants, over-the-ankle boots and seat belt at all times.

7. Sit in the driver's seat and fasten the seat belt.

8. Make sure all cab nets are properly secured.

9. Place the transmission in PARK.

10. Start the engine.

55

OPERATION

New Operator Driving Procedures

11. Apply the brakes and shift into low gear.

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

13. Keeping both hands on the steering wheel, slowly release the brakes
and depress the throttle with your right foot to begin driving.

14. Drive slowly at first. On level surfaces, practice starting, stopping,
turning, maneuvering, using the throttle and brakes and driving in
reverse. Learn how the vehicle handles when making both left and
right turns at a slow speed.

WARNING! Operating in TURF mode (if equipped) 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.

15. Increase speed only after mastering all maneuvers at a slow speed.

16. After you become skilled at making turns and begin to operate at
faster speeds, follow these precautions:

• Avoid sharp turns.

• Never turn while applying heavy throttle.

• Never make abrupt steering maneuvers.

• Operate at speeds appropriate for your skills, the conditions and
the terrain.

• DO NOT do power slides, “donuts”, jumps or other driving
stunts.

56

OPERATION

Turning the V ehicle

Your vehicle is equipped with a
solid rear axle, which drives both
rear wheels equally at all times.
This means that the wheel on the
outside of the turn must travel a
greater distance than the inside
wheel when turning and the inside
tire must slip traction slightly.

To turn the vehicle, rotate the
steering wheel in the direction of
the turn.

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

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

57

OPERATION

Driving on Slippery Surfaces

When driving on slippery surfaces such as wet trails, loose gravel, or
ice, be alert for the possibility of skidding and sliding. Follow these
precautions when encountering slippery conditions:

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

2. Slow down before entering slippery areas.

3. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.

4. Engage all-wheel drive before wheels begin to lose traction.

NOTICE: Severe damage to the drive train may occur if the AWD is engaged

while the wheels are spinning. Always allow the wheels to stop
spinning before engaging AWD.

5. Correct a skid by turning the steering wheel in the direction of the
skid. Never apply the brakes during a skid.

Sideways

skid

Turn in

direction of

skid

58

OPERATION

Driving Uphill

Whenever traveling uphill, follow these precautions:

1. Always check the terrain carefully before ascending any hill. Never
drive on hills with excessively slippery or loose surfaces.

2. Never operate in TURF mode (if equipped) while operating on a hi ll

or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.

3. Avoid excessively steep hills. If ascending a steeper grade is

unavoidable, engage all-wheel drive before ascending.

4. Drive straight uphill.

5. Proceed at a steady rate of speed and throttle opening. Never open

the throttle suddenly.

6. Avoid unnecessary changes in speed or direction.

7. Never go over the crest of a hill at high speed. An obstacle, a sharp

drop, or another vehicle or person could be on the other side of the
hill.

8. If the vehicle stalls while climbing a hill, apply the brakes. Place the

transmission in reverse and slowly allow the vehicle to roll straight
downhill while applying light brake pressure to control speed.

59

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a hill is unavoidable, follow these precautions:

1. Engage all-wheel drive.

2. Never operate in TURF mode (if equipped) while operating on a hi ll
or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.

3. Drive slowly and use extreme caution.

4. If the vehicle begins to overturn, or if it feels as if it may overturn,
immediately turn downhill.

5. Avoid obstacles and changes in terrain that may lower or raise one
side of the vehicle or cause the vehicle to slide.

6. If the vehicle begins to slide downhill, immediately turn downhill to
stop the slide, or stop the vehicle and maneuver slowly and
carefully until the vehicle can be driven straight downhill.

60

OPERATION

Driving Downhill

Whenever descending a hill, follow these precautions:

1. Avoid excessively steep hills.

2. Never operate in TURF mode (if equipped) while operating on a hi ll
or other irregular terrain. Always move the AWD switch to AWD
before ascending or descending a hill.

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

4. Always check the terrain carefully before descending a hill. Never
drive on hills with excessively slippery or loose surfaces.

5. Always descend a hill with the transmission in forward gear. Never
descend a hill with the transmission in neutral.

6. Avoid traveling down a hill at an angle, which would cause the
vehicle to lean sharply to one side. Travel straight downhill.

7. Apply the brakes lightly to aid in slowing.

61

OPERATION

Driving Through Water

Your vehicle can operate
through water with a
maximum recommended depth
equal to floor level. Follow
these precautions when
operating through water:

1. Determine water depth and
current before entering
water.

2. Choose a crossing where

the water level is lowest
and where both banks
have gradual inclines.
Never operate in water that
exceeds the maximum
recommended depth.

WARNING! The large tires on your vehicle may cause the vehicle to float in
deep or fast-flowing water, which could result in loss of traction, loss of control,
rollover or accident.

3. Wet brakes may have reduced stopping ability. After leaving water,

test the brakes. Apply them lightly several times while driving
slowly. The friction will help dry out the pads.

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

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 79. Give special attention to engine
oil, transmission oil, demand drive fluid, rear gearcase oil (if
equipped) and all grease fittings.

If your vehicle becomes immersed or is operated in water that
exceeds the floor level, take it to your POLARIS dealer for service
before starting the engine. If it's impossible to bring the vehicle to
your dealer before starting the engine, perform the service outlined
on page 115, and take the vehicle to your dealer at the first
opportunity.

Floor Level

62

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
hazards 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. Avoid operating over large obstacles such as large rocks and fallen
trees. If unavoidable, use extreme caution and operate slowly.

63

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Apply the throttle lightly. Never apply throttle suddenly .

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid making sharp turns.

Parking on an Incline

A rolling vehicle can result in
serious injury. Avoid parking on
an incline. If parking on an
incline is unavoidable, follow

these precautions:

1. Place the transmission in
PARK.

2. Turn the engine off.

3. Block the rear wheels on the

downhill side, or park the
vehicle in a sidehill position
instead.

64

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:

Never exceed the stated load capacity for this vehicle.
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, accessories, loads in the rack or box and the load on the trailer tongue.
The combined weight of these items must not exceed the maximum weight
capacity.

Always load the cargo box with the load as far forward and as low as possible.
When operating over rough or hilly terrain, reduce speed and cargo to maintain

stable driving conditions.
Always operate the vehicle with extreme care when hauling or towing loads.

Slow down and drive in the lowest gear available.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create

unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When

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

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

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

DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. Vehicle
should never exceed 10 MPH (16 km/h) while towing a load on a level grass
surface. Vehicle speed should never exceed 5 MPH (8 km/h) when towing loads
in rough terrain, while cornering, or while ascending or descendin g a hill.

Carrying a passenger in the cargo box could
result in a fall from the vehicle or contact with
moving components. Never allow a
passenger to ride in the cargo box.

WARNING

65

OPERATION

Hauling Cargo

Your POLARIS vehicle has been designed to carry or tow specific
capacities. Reduce speed and allow a greater distance for braking when
carrying cargo.

Loads should be centered and carried as low as possible in the box. For
stability on rough or hilly terrain, reduce both speed and cargo. Exercise
caution if the cargo load extends over the side of the box.

Always read and understand the load distribution warnings listed on
warning labels and in this manual. Never exceed the maximum
capacities specified for your vehicle. See page 128.

Belt Life

To extend belt life, use low gear when hauling or towing heavy cargo.

66

OPERATION

Towing Loads

Towing improperly can alter vehicle handling and may cause loss of control or
brake instability.

Always follow these precautions when towing:

1. Never load more than 150 lbs. (68.1 kg) tongue weight on the
towing bracket.

2. When towing a disabled vehicle, place the disabled vehicle’s

transmission in neutral. Do not operate the vehicle faster than 10
MPH (16 km/h) when towing.

3. Towing a trailer increases braking distance. Do not operate the

vehicle faster than 10 MPH (16 km/h) when towing.

4. Do not tow more than the recommended weight for the vehicle.

5. Attach a trailer to the trailer hitch bracket only. Do not attach a

trailer to any other location, which could result in loss of control of
the vehicle.

6. The total load (operator, accessories, cargo and weight on hitch)

must not exceed the maximum weight capacity of the vehicle.

Total Towed

Load Weight

(Level Ground)

Total Towed

Load Weight

(15° grade)

Total Hitch

Vertical

Weight

Maximum

Towing

Speed

1500 lbs.

(681 kg)

850 lbs.

(386 kg)

150 lbs.

(68.1 kg)

10 MPH

(16 km/h)

WARNING

67

WINCH GUIDE

These safety warnings and instructions apply if your vehicle came
equipped with a winch or if you choose to add an accessory winch to
your vehicle.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.

Your winch may have a cable made of either wire rope or specially
designed synthetic rope. The term “winch cable” will be used for either
unless noted otherwise.

Winch Safety Precautions

1. Read all sections of this manual.

2. Never use alcohol or drugs before or while operating the winch.

3. Never allow children under 16 years of age to operate the winch.

4. Always wear eye protection and heavy gloves when operating the
winch.

5. Always keep body, hair, clothing and jewelry clear of the winch
cable, fairlead and hook when operating winch.

6. Never attempt to “jerk” a load attached to the winch with a moving
vehicle. See the Shock Loading section on page 76.

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

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

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

WARNING

68

WINCH GUIDE

Winch Safety Precautions

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

11. Always align the vehicle and winch with the load directly in front of
the vehicle as much as possible. Avoid winching with the winch
cable at an angle to the winching vehicle’s centerline whenever
possible.

12. If winching at an angle is unavoidable, follow these precautions:

A. Look at the winch drum occasionally . Never let the winch cable “stack”

or accumulate at one end of the winch drum. Too much winch cable at
one end of the winch drum can damage the winch and the winch cable.

B. If stacking occurs, stop winching. Follow step 15 on page 74 to feed

and rewind the cable evenly before continuing the winch operation.

13. Never winch up or down at sharp angles. This can destabilize the
winching vehicle and possibly cause it to move without warning.

14. Never attempt to winch loads that weigh more than the winch’s
rated capacity.

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

16. Never touch, push, pull or straddle the
winch cable while winching a load.

17. Never let the winch cable run through
your hands, even if wearing heavy
gloves.

69

WINCH GUIDE

Winch Safety Precautions

18. Never release the clutch on the winch when the winch cable is under
load.

19. Never use the winch for lifting or transporting people.

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

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

22. Always inspect your winch and winch cable before each use.

23. Never winch the hook fully into the winch. This can cause damage
to winch components.

24. Unplug the remote control from the vehicle when the winch is not in
use to prevent inadvertent activation and use by unauthorized
persons.

25. Never grease or oil the winch cable. This will cause the winch cable
to collect debris that will shorten the life of the cable.

70

WINCH GUIDE

Winch Operation

Read the Winch Safety Precautions in the preceding pages before using
your winch.

Tip: Consider practicing the operation and use of your winch before you actually

need to use it in the field.

Improper winch use can result in SEVERE INJURY or DEATH. Always follow all
winch instructions and warnings in this manual.

Each winching situation is unique.

• Take your time to think through the winching you are about to do.

• Proceed slowly and deliberately.

• Never hurry or rush during winching.

• Always pay attention to your surroundings.

• You may need to change your winching strategy if it is not working.

• Always remember that your winch is very powerful.

• There are simply some situations that you and your winch will not be able
to deal with. Do not be afraid to ask others to help when this happens.

1. Always inspect the vehicle, winch, winch cable and winch controls
for any signs of damage or parts in need of repair or replacement
before each use. Pay particular attention to the first 3 feet (1 meter)

of winch cable if the winch is being used (or has been used) for lift­ing an accessory plow assembly. Promptly replace any worn or

damaged cable.

2. Never operate a winch or a vehicle in need of repair or service.

3. Always apply your

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

WARNING

Hook Strap

71

WINCH GUIDE

Winch Operation

4. Always use the hook strap when
handling the hook.

WARNING! Never put your fingers into
the hook. This could lead to SEVERE
INJURY.

A. Attach the hook itself onto the

load or use a tow strap or chain
to secure the load to the winch
cable.

Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to

stretch.

WARNING! Never use a recovery strap when winching due to the excessive
energy that can be released if the winch cable breaks. This can result in
SEVERE INJURY or DEATH. See the Shock Loading section on page 76.

B. Never hook the winch cable back onto itself. This will damage the

winch cable and may result in winch cable failure.

WARNING! Replace the winch cable at the first sign of damage to prevent
SEVERE INJURY or DEATH in the event of failure. For your safety, always
replace POLARIS winch parts (including the cable) with genuine POLARIS
replacement parts available at your authorized POLARIS dealer.

C. If possible, keep the winch cable aligned with the centerline of the

winching vehicle. This will help the spooling of the winch cable and
reduce the load on the fairlead.

D. If freeing a stuck vehicle by attaching to a tree, use an item such as a

tow strap to avoid damaging the tree during winch operation. Sharp
cables and chains can damage and even kill trees. Please remember
to TreadLightly® (treadlightly.org).

E. Before operating the winch, be sure

that the safety latch on the winch
cable hook is fully seated when the
load is attached.

F. Never operate your winch with a

damaged hook or latch. Always
replace damaged parts before using
the winch.

NO YES

NO

YES

72

WINCH GUIDE

Winch Operation

5. Never remove the hook strap from the hook.

6. Release the winch clutch and pull out the winch cable.

7. Pulling out as much cable as possible maximizes the winch’ s pulling
capacity. Always be sure that at least five (5) full turns of winch
cable are wrapped around the winch drum at all times. The friction
provided by this wrapped cable allows the drum to pull on the
winch cable and move the load.

8. Read and adhere to the following information for winch damping to
ensure safe winch use.

A. In order to absorb energy that could be released by a winch cable

failure, always place a “damper” on the winch cable. A damper can be
a heavy jacket, tarp, or other soft, dense object. A damper can absorb
much of the energy released if a winch cable breaks when winching.
Even a tree limb can help as a damper if no other items are available to
you.

B. Lay the damper on top of the mid-point of the winch cable length that is

spooled out.

C. On a long pull, it may be necessary to stop winching so that the

damper can be repositioned to the new mid-point of the winch cable.
Always release the tension on the winch cable before repositioning the
damper.

D. Avoid being directly in line with the winch cable whenever possible.

Also, never permit others to stand near or in line with the winch cable
during winch operation.

9. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.

10. Never use straps, chains or other rigging items that are damaged or
worn.

73

WINCH GUIDE

Winch Operation

11. The ONLY time a winch-equipped vehicle should be moving when
using the winch is when that vehicle itself is stuck. The winch­equipped vehicle should NEVER be in motion to “shock” load the
winch cable in an attempt to move a second stuck vehicle. See the
Shock Loading section on page 76. For your safety, always follow
these guidelines when winching a vehicle free:

A. Release the winch clutch and spool out the necessary length of winch

cable.

B. Align the winch cable as close as possible to the winching vehicle’s

centerline.

C. Attach the winch cable hook to the anchor point or the stuck vehicle’s

frame following instructions in this manual.
D. Re-engage the clutch on the winch.
E. Slowly winch in the slack in the winch cable.
F. Select the proper vehicle ge ar to propel the stuck vehicle in the

direction of winching.
G. Shift to the lowest gear available on the stuck vehicle.
H. Slowly and carefully apply vehicle throttle and winch together to free

the vehicle.
I. Stop winching as soon as the stuck vehicle is able to propel itself

without the help of the winch.
J. Detach the winch cable hook.
K. Rewind the winch cable evenly back onto the winch drum following the

instructions in this manual.

12. Never attempt to winch another stuck vehicle by attaching the
winch cable to a suspension component, brush guard, bumper or
cargo rack. Vehicle damage may result. Instead, attach the winch to
a strong portion of the vehicle frame or hitch.

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

74

WINCH GUIDE

Winch Operation

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

15. After winching is complete, especially if winching at an angle, it
may be necessary to re-distribute the winch cable across the winch
drum. You will need an assistant to perform this task.

A. Release the clutch on the winch.
B. Feed out the winch cable that is unevenly bunched up in one area.
C. Re-engage the winch clutch.
D. Have an assistant pull the winch cable tightly with about 100 lbs. (45

kg) of tension using the hook strap.

E. Slowly winch the cable in while your assistant moves the end of the

winch cable back and forth horizontally to evenly distribute the winch
cable on the drum.

F. Doing this reduces the chances of the winch cable “wedging” itself

between lower layers of winch cable.

75

WINCH GUIDE

Winch Cable Care

For your safety, always replace POLARIS winch parts (including the
cable) with genuine POLARIS replacement parts available at your
authorized POLARIS dealer.

WARNING! Use of worn or damaged cable could lead to sudden failure and
SEVERE INJURY.

1. Always inspect your winch before each use. Inspect for worn or
loose parts including mounting hardware. Never use the winch if
any part needs repair or replacement.

2. Always inspect your winch cable before each use. Inspect for worn

or kinked winch cable.

A. A kinked winch cable made of

wire rope is shown at right. Even
after being “straightened out,”
this cable has already been
permanently and severely
damaged. Promptly discontinue
use of a winch cable in this
condition.

B. A kinked winch cable made of

wire rope that has been
“straightened out” is shown at
right. Even though it may look
usable, the cable has been
permanently and severely damaged. It can no longer transmit the load
that it could prior to kinking. Promptly discontinue use of a winch cable
in this condition.

C. A winch cable made of

synthetic rope should be
inspected for signs of fraying.
Replace the cable if fraying is
observed (shown at right).
Promptly discontinue use of a
winch cable in this condition.

D. Also replace the winch cable if there are fused or melted fibers. Such

an area of the synthetic rope will be stiff and appear smooth or glazed.
Promptly discontinue use of a winch cable in this condition.

A

B

C

76

WINCH GUIDE

Shock Loading

WARNING! Your winch cable is very strong but it is NOT designed for dynamic,

or “shock” loading. Shock loading may tension a winch cable beyond its strength
and cause the cable to break. The end of a broken winch cable under such high
loading can cause SEVERE INJURY or DEATH to you and other bystanders.

Winch cables are designed to NOT absorb energy . This is true of both
wire-rope and synthetic-rope winch cables.

1. Never attempt to “jerk” a load with the winch. For example, never
take up slack in the winch cable by moving the winching vehicle in
an attempt to move an object. This is a dangerous practice. It gener­ates high winch cable loads that may exceed the strength of the
cable. Even a slowly moving vehicle can create large shock loads in
a winch cable.

WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.

2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).

This puts extra load on the winch, winch cable, and generates
excessive heat from the motor. This is a form of shock loading.

3. Never tow a vehicle or other object with your winch. Towing an

object with a winch produces shock loading of the cable even when
towing at slow speeds. Towing from a winch also positions the
towing force high on the vehicle. This can cause instability of the
vehicle and possibly lead to an accident.

4. Never use recovery straps with your winch. Recovery straps are

designed to stretch and can store energy. This stored energy in the
recovery strap is released if a winch cable fails making the event
even more hazardous. Similarly, never use elastic “bungie” cords
for winching.

5. Never use the winch to tie down a vehicle to a trailer or other

transportation vehicle. This type of use also causes shock loading
that can cause damage to the winch, winch cable, or vehicles used.

Your winch cable is designed and tested to withstand the loads
produced by the winch motor when operated from a stationary
vehicle. Always remember that the winch and winch cable are NOT
designed for shock loading.

77

WINCH GUIDE

Winch Maintenance and Service Safety

WARNING! Improper or lack of winch maintenance and service could lead to

SEVERE INJURY or DEATH. Always follow all winch instructions and warnings
in this manual.

1. Always inspect your winch before each use. Inspect for worn or
kinked winch cable. Also inspect for worn or loose parts including
mounting hardware.

2. Permit your winch motor to cool down prior to servicing your

winch.

3. Never work on your winch without first disconnecting the battery

connections to prevent accidental activation of the winch

4. For your safety, always replace POLARIS winch parts (including

the cable) with genuine POLARIS replacement parts available at
your authorized POLARIS dealer.

5. Some winch models use wire rope as the winch cable. Other

winches use a specially designed synthetic rope as the winch cable.

6. Never replace a synthetic-rope winch cable with a consumer-grade

polymer rope such as can be purchased in a hardware store.
Although they may look similar, they are NOT alike. A polymer
rope not designed for winch use will stretch and store excessive
energy when winching.

WARNING! Failure of a stretched rope under winching conditions will release
all of the stored energy. This will increase the chances of SEVERE INJURY or
DEATH.

78

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 arrester that was tested and qualified
to be in accordance with the USFS standard 5100-1C. Federal law
requires that this spark arrester 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 420. 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 inside of the lower left frame tube
(below driver’s foot area).

Electromagnetic Interference

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

directives 97/24/EC and 2004/108/EC.
Non-ionizing Radiation: This vehicle emits some electromagnetic

energy. People with active or non-active implantable medical devices
(such as heart monitoring or controlling devices) should review the
limitations of their device and the applicable electromagnetic standards
and directives that apply to this vehicle.

Emissions Label

(inside of frame tube)

79

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 142.

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.

Vehicles subjected to heavy or severe use patterns must be inspected and
serviced more frequently.

Severe Use Definition

• Frequent immersion in mud, water or sand

• Frequent or prolonged operation in dusty environments

• 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 POLARIS dealer.

80

MAINTENANCE

Periodic Maintenance Chart

Maintenance Chart Key

WARNING! Improperly performing the procedures marked with a “D” could

result in component failure and lead to serious injury or death. Have an
authorized POLARIS dealer perform these services.

Symbol Description

Ź 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)

D Have an authorized POLARIS dealer perform these services.

81

MAINTENANCE

Periodic Maintenance Chart

Perform all services at whichever maintenance interval is reached first.

Ź Perfor m these procedures more often for vehicles subjected to severe use.

E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

Steering

Pre-Ride

Inspect and make
adjustments as need ed.
See Pre-Ride Checklist on
page 48.

Front suspension
Rear suspension
Tires
Brake fluid level
Brake pedal travel
Brake system
Wheels/fasteners
Frame fasteners
Engine oil level
Intake pre-filters
Winch (if

equipped)

- - See pages 67-77

Coolant - Daily - Check level daily, change

coolant every 2 years

Headlamp/tail
lamp

- Daily - Check operation; apply
dielectric grease if replacing

Ź

E

Air filter,
main element

- Weekly - Inspect; replace as needed

Ź

D

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

Ź

E

Engine breather 25 H Monthly 150 (250) Inspect; replace if necessary

Battery 25 H Monthly 250 (400) Check terminals; clean; test

Ź Engine oil change 25 H 1 M - Break-in oil and filter change
Ź Demand drive fluid 25 H 1 M - Break-in oil level check
Ź Transmission oil

(main gearcase)

25 H 1 M - Break-in oil level check

82

MAINTENANCE

Periodic Maintenance Chart

Ź Perfor m these procedures more often for vehicles subjected to severe use.

E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

Ź

E

Throttle cable 50 H 6 M 300 (500) Inspect; adjust; lubricate;

replace if necessary

E Throttle body air

intake ducts/flange

50 H 6 M 300 (500) Inspect duct for proper seal-

ing/air leaks

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

cables, etc.

Ź Oil lines, fasteners

(if equipped)

50 H 6 M 500 (800) Inspect for leaks and loose

fittings

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

D Steering 50 H 6 M 500 (800) Lubricate

Ź Front Suspension 50 H 6 M 500 (800) Lubricate
Ź Rear Suspension 50 H 6 M 500 (800) Lubricate

Cooling system 50 H 6 M 500 (800) Inspect coolant strength

seasonally; pressure test
system yearly

Ź Engine oil change 100 H 6 M - Change the oil and filter

DEFuel system 100 H 12 M 600 (1000) Check for leaks at tank cap,

lines, filter, pump, throttle
body; replace lines every two
years

Ź

E

Spark plug 100 H 12 M 600 (1000) Inspect; replace as needed

Ź Demand drive fluid 100 H 12 M - Change fluid
Ź Transmission oil

(main gearcase)

100 H 12 M - Change fluid

83

MAINTENANCE

Periodic Maintenance Chart

Ź Perfor m these procedures more often for vehicles subjected to severe use.

E Emission-Related Service
D Have an authorized POLARIS dealer perform these services.

Item Maintenance Interval

(whichever comes first)

Remarks

Hours Calendar Miles (Km)

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

surfaces

Ź Cooling Hoses 100 H 12 M 1000 (1600) Inspect for leaks
Ź Engine mounts 100 H 12 M 1000 (1600) Inspect

Exhaust muffler/
pipe

100 H 12 M 1000 (1600) Inspect

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

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

D Clutches (drive

and driven)

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

parts

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

D Front wheel

bearings

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

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

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

Ź

E

Valve clearance 500 H - 5000 (8000) Inspect; adjust as needed

D Toe adjustment - Inspect periodically; adjust

when parts are replaced

Headlight aim - Adjust as needed

84

MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79, or more often under
severe use, such as wet or dusty conditions. Items not listed in the chart
should be lubricated at the general lubrication interval.

Item Lube Method

Engine Oil PS-4 5W-50 4-Cycle Oil Add to proper level on dipstick.

See page 87.

Brake Fluid DOT 4 Brake Fluid Maintain level between fill lines.

See page 108.

Transmission Oil
(Main Gearcase)

AGL Gearcase Lubricant &
Transmission Fluid

See page 91.

Demand Drive Fluid
(Front Gearcase)

Demand Drive Fluid See page 90.

Prop Shaft U-Joint Grease Locate fittings and grease.
Rear Control Arm Pivot

Bushings, Front A-Arm
Bushings

All Season Grease or grease
conforming to NLGI No. 2

Locate fittings and grease.

Stabilizer Bar Bushings,
Tie Rod Bushings, Ball
Joint Boots

All Season Grease or grease
conforming to NLGI No. 2

Locate fittings and grease.

Prop Shaft

Grease Fitting

85

MAINTENANCE

Lubrication Recommendations

Rear Control

Arm Pivot

Bushings

Stabilizer Bar

Bushings

Front A-Arm

Bushing

Tie Rod

Bushing

Ball Joint

Boot

86

MAINTENANCE

Engine Oil

Oil Recommendations

POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W­50 4-cycle oil for this engine.

WARNING! Vehicle operation with insufficient, deteriorated, or contaminated
engine oil will cause accelerated wear and may result in engine seizure,
accident, and injury . Always perform the maintenance procedures as outlined in
the Periodic Maintenance Chart.

Oil may need to be changed more frequently if POLARIS PS-4 engine
oil is not used. Follow the manufacturer's recommendations for ambient
temperature operation. See page 130 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.

87

MAINTENANCE

Engine Oil

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 79. Always use the recommended
engine oil.

NOTICE: Allowing dirt or debris to enter the engine can result in serious engine

damage. Always clean away all dirt and debris from the dipstick area
before removing the dipstick.

Oil Check

The oil dipstick is located on the
lower engine, behind the seat.
Access the dipstick through the right
rear wheel well. Remove the
dipstick to check the oil level and to
add oil. An additional oil fill hole is
located at the top of the engine. Add
oil through either the dipstick hole
or the upper fill hole. Access the
upper fill hole cap through the cargo
box access panel.

1. Position the vehicle on a level
surface.

2. Place the transmission in P A RK.

3. Always clean away all dirt and

debris from the dipstick area
before removing the dipstick.
Remove the dipstick. Wipe it
dry with a clean cloth.

4. Reinstall and tighten the

dipstick.

5. Remove the dipstick and check

the oil level.

6. Add the recommended fluid as

needed. Maintain the oil level in
the safe range between the
FULL and ADD marks. Do not
overfill.

7. Reinstall and tighten the dipstick.

Oil Dipstick (Check/Fill)

Upper Oil Fill

Full

Add

88

MAINTENANCE

Engine Oil

Oil and Filter Change

Always check and change the oil at the intervals outlined in the Periodic
Maintenance Chart beginning on page 79. Always change the oil filter
whenever changing oil.

The engine drain plug is located
on the bottom of the crankcase.

1. Position the vehicle on a level
surface. Place the
transmission in PARK. Apply
the brakes.

2. Start the engine. Allow it to

idle for two to three minutes.
Stop the engine.

3. Clean the area around the

drain plug.

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

4. Place a drain pan beneath

engine crankcase and remove
the drain plug.

5. Allow the oil to drain

completely.

6. Install a new sealing washer

on the drain plug.

Tip: The sealing surfaces on drain

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

7. Reinstall the drain plug. Torque to 11-13 ft. lbs. (14.5-17.5 Nm).

Spring

Filter

Sealing

Washer

Drain

Plug

O-Ring

Filter Cover

89

MAINTENANCE

Engine Oil

Oil and Filter Change

8. Using a clean dry cloth, clean the oil filter cover on the crankcase.

9. Place shop towels beneath the filter cover to catch oil drips. Remove
the cover screws and remove the cover to access the oil filter.

10. Remove the oil filter and spring, retaining the spring for
reinstallation.

11. Using a clean dry cloth, clean the surface of the crankcase.

12. Lubricate the o-ring for the new filter with a film of fresh engine oil.
Check to make sure the o-ring is in good condition. Install the o­ring to the filter cover.

13. Reinstall the oil filter spring, then install the new filter.

14. Reinstall the oil filter cover and o-ring. Torque the screws to 88 in.
lbs. (10 Nm).

15. Fill the sump with 1.75 quarts (1.65 l) of the recommended oil.

16. Reinstall the upper fill cap (if removed) and tighten the dipstick.

17. Make sure the transmission is in PARK. Apply the brakes.

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

19. Stop the engine. Inspect for leaks.

20. Re-check the oil level on the dipstick and add oil as necessary to
bring the level to the upper mark on the dipstick.

21. Dispose of used filter and oil properly.

90

MAINTENANCE

Gearcases

Demand Drive Unit (Front Gearcase)

Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 92 for recommended lubricants,
capacities and torque specifications.

Fluid Check

The fill plug is located on the
bottom right side of the
demand drive unit. Access the
fill plug through the right front
wheel well. Maintain the fluid
level even with the bottom
thread of the fill plug hole.

1. Position the vehicle on a
level surface.

2. Remove the fill plug.

Check the fluid level.

3. Add the recommended

fluid to the bottom thread
of the fill plug hole.

4. Reinstall the fill plug.

Torque to specification.

Fluid Change

The drain plug is located on the bottom of the gearcase.

1. Remove the fill plug.

2. Place a drain pan under the drain plug.

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

4. Clean the drain plug. If the o-ring is damaged, install a new o-ring.

5. Reinstall the drain plug. Torque to specification.

6. Add the recommended fluid to the bottom thread of the fill plug

hole.

7. Reinstall the fill plug. Torque to specification.

8. Check for leaks. Discard used fluid properly.

Fill Level

Fill Plug

Drain Plug

91

MAINTENANCE

Gearcases

Transmission (Main Gearcase)

Always check and change the fluid at the intervals outlined in the
Periodic Maintenance Chart beginning on page 79. Refer to the
Gearcase Specifications Chart on page 92 for recommended lubricants,
capacities and torque specifications.

Fluid Check

The fill plug is located on the rear of
the gearcase. Maintain the fluid level at
the bottom of the fill plug hole.

1. Position the vehicle on a level
surface.

2. Remove the fill plug. Check the

fluid level.

3. Add the recommended fluid to the

bottom of the fill plug hole. Do not
overfill.

4. Reinstall the fill plug. Torque to

specification.

Fluid Change

The drain plug is located on the bottom
of the gearcase between the rear tires.
Access the drain plug through the drain
hole in the skid plate.

1. Remove the fill plug.

2. Place a drain pan under the drain

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

3. Clean the drain plug. Reinstall the drain plug with a new o-ring.

Torque to specification.

4. Add the recommended fluid to the bottom of the fill plug hole. Do

not overfill.

5. Reinstall the fill plug. Torque to specification.

6. Check for leaks. Discard used fluid properly.

Fill Plug

Drain Plug

(between rear tires)

92

MAINTENANCE

Gearcases

Gearcase Specification Chart

Use of other fluids may result in improper operation of components. See
page 130 for the part numbers of POLARIS products.

Spark P lug

Spark Plug Gap/Torque

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. Always use POLARIS-recommended spark plugs. Refer to
the specifications section beginning on page 128.

Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine is warmed up and
the vehicle is driven at higher speeds. Immediately check the spark plug
for correct color. See page 93.

CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.

Gearcase Lubricant Capacity Fill Plug

Torque

Drain Plug/
Level Check
Plug Torque

Transmission

(Main Gearcase)

AGL Gearcase

Lubricant &

Transmission

Fluid

44 oz. (1300 ml) 10-14 ft. lbs.

(14-19 Nm)

10-14 ft. lbs.

(14-19 Nm)

Demand Drive Unit

(Front Gearcase)

Demand Drive

Fluid

9 oz.

(265 ml)

8-10 ft. lbs.

(11-13.6 Nm)

8-10 ft. lbs.

(11-13.6 Nm)

Electrode Gap New Plug Torque Used Plug Torque

0.7-0.8 mm 7.5 ft. lbs. (10 Nm) 7.5 ft. lbs. (10 Nm)

93

MAINTENANCE

Spark P lug

Spark Plug Removal and Replacement

1. Remove the cargo box access panel.

2. Remove the spark plug cap.

3. Using the spark plug wrench provided in the tool kit, remove the
plug by rotating it counter-clockwise.

4. Reverse the procedure for spark plug installation. Torque to
specification. See page 92.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light 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.

Wet Fouled 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, use
of non-recommended injection oil or incorrect throttle body
adjustments.

94

MAINTENANCE

Fuses

If the engine stops or will not start, or if you experience other electrical
failures, a fuse may need replacement. Locate and correct any short
circuits that may have caused the blown fuse, then replace the fuse.

The fuse box is located under the seat. Spare fuses are provided in the
fuse box.

Main Fuse Feature Supported

20A Lights: Headlights, Taillights
20A Drive: AWD
20A Accessory: Winch Switch, 12V Power Receptacle
10A Fuel Pump
20A Electronic Engine Control, Starting
30A Engine Control

Fuse Box

95

MAINTENANCE

Fuses

Fuse Box

1. Remove the seat to access

the fuse box.

2. Squeeze the cover release
tabs inward and remove the
fuse box cover.

3. Remove the suspect fuse
from the fuse panel. If the
fuse is blown, install a new
fuse with the same amperage
rating.

4. Reinstall the fuse box cover.

5. Reinstall the seat.

Release Tabs

96

MAINTENANCE

Cooling System

Operation

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

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

Tip: Some coolant level drop on new vehicles is normal as the system is purging

itself of trapped air. Observe coolant levels and maintain as recommended
by adding coolant to the overflow bottle.

Adding or Changing Coolant

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely drained every two years and a
fresh mixture of antifreeze and water added.

POLARIS recommends the use of POLARIS Antifreeze 60/40 premix
or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. POLARIS Antifreeze is already premixed
and ready to use. Do not dilute with water. See page 130 for the part
numbers of POLARIS products.

Tip: Always follow the manufacturer's mixing recommendations for the freeze

protection required in your area.

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