Polaris Sportsman BIG BOSS 6x6, Sportsman 9922233, Sportsman BIG BOSS 6X6 800 EFI User Manual

Pantone 426 C

Sportsman

Big Boss 6X6

Owner's Manual

for Maintenance and Safety

Read this manual carefully. It contains important safety information.

Operation is prohibited for those under 16 years of age.

This is an adult vehicle only.

WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Pantone 426 C

Improper vehicle use can result in SEVERE INJURY or DEATH.

NEVER:
S Operate on public roads. A collision can occur with another

vehicle.
S Carry passengers. Passengers affect balance and steering and

increase risk of losing control.
S USE ALCOHOL or DRUGS before or while operating this

vehicle.

S Operate at speeds too fast for your skills or the conditions.
S Operate this vehicle on HILLS steeper than 25 degrees. To

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

ALWAYS:

S Use an approved HELMET AND PROTECTIVE GEAR.
S Avoid paved surfaces. Pavement may seriously affect

handling and control.
S Use proper RIDING TECHNIQUES to avoid vehicle

overturns on hills and rough terrain and in turns.
S Use OVERRIDE for reverse speed limiter with caution. To

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

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

PARKING BRAKE may relax when used for more than 5
minutes. When parking on grades, leave shift in forward.

LOCATE AND READ OWNER'S MANUAL.

FOLLOW ALL INSTRUCTIONS AND WARNINGS.

For your nearest Polaris dealer,
call 1-800-POLARIS
or visit www.polarisindustries.com
Polaris Sales Inc.,
2100 Hwy. 55, Medina, MN 55340
Phone [phone]
Part No. 9922233 Rev 03
Printed in USA

WELCOME

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

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER

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

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

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

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

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

®

utility vehicles

®

®

(MSD)

1

POLARIS, THE WAY OUT, SPORTSMAN and BIG BOSS are registered trademarks
of Polaris Industries Inc.

Copyright 2009 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrep­ancies may result between the actual vehicle and the information presented in this publi­cation. Depictions and/or procedures in this publication are intended for reference use
only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse
of the depictions and/or procedures contained within, whether whole or in part, is
expressly prohibited.

Printed in U.S.A.
2010 SPORTSMAN BIG BOSS 6X6 800 EFI Owner’s Manual
P/N 9922233

2

TABLE OF CONTENTS

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

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

Features and Controls . . . . . . . . . . . . . . . . . . . 26

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

Emission Control Systems . . . . . . . . . . . . . . . 66

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 118

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 122

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 124

Declaration of Conformity . . . . . . . . . . . . . . . 125

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 134

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

3

INTRODUCTION

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

The safety alert symbol indicates a potential personal injury hazard.

WARNING

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

CAUTION

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

NOTICE

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

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

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

4

INTRODUCTION

WARNING

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

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

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

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

• Never permit a guest to operate this vehicle unless the guest has read this
manual and all product labels and has completed a certified safety training
course.

5

INTRODUCTION

####

VIN

Engine Serial Number

Key Number

Vehicle Identification Numbers

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

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

6

SAFETY

Safety Training

ATV safety training is a top priority for Polaris. Polaris strongly
encourages you and any family members who will be riding the ATV to
take a training course.

If you purchased a new Polaris ATV in the United States, your dealer
provided instruction to you about the authorized ATV RiderCourse
that is available to you and your eligible family members. This training
is included in the purchase price of your ATV. You were also provided
with printed materials that explain safe operating procedures. You
should review this information on a regular basis.

If you purchased a used Polaris ATV in the United States, you can enroll

sm

in the ATV RiderCourse

for a fee. Call ATV Enrollment Express at

[phone] or visit www.atvsafety.org.
If you purchased a Polaris ATV outside the United States, please contact

your dealer or local law enforcement agencies for information about
safety training.

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

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

FOR MORE INFORMATION ABOUT ATV SAFETY in the United
States, call the Consumer Product Safety Commission at 1-800­638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call
Polaris at 1-800-342-3764.

sm

7

SAFETY

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

Safe Riding Gear

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

Helmet

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

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

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

8

SAFETY

Safe Riding Gear

Eye Protection

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

Gloves

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

Boots

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

Clothing

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

Equipment Modifications

We strongly recommend that consumers do not install on a Polaris vehi­cle any equipment that may increase the speed or power of the vehicle,
or make any other modifications to the vehicle for these purposes.

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

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.

9

SAFETY

WARNING

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

Operating Without Instruction

Operating this 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.

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

Never permit a guest to operate the vehicle unless
the guest has read this manual and all product
labels and has completed a certified safety training
course.

Age Restrictions

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

Even though a child may be within the
recommended age group for operating some
Polaris vehicles, he/she may not have the skills,
abilities, or judgment needed to operate this
vehicle safely and could be susceptible to accident
or injury.

10

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

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

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

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

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

Exposure to Exhaust

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

The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.

Failure to Inspect Before Operating

Failure to inspect and verify that the 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.

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

11

SAFETY

Safety Warnings

Protective Apparel

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

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

Using Alcohol or Drugs

Operating the 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.

Carrying a Passenger

Carrying a passenger greatly reduces the
operator's ability to balance and control the
vehicle, which may result in an accident or
overturn.

Never carry a passenger on this vehicle.

12

Safety Warnings

Operating on Pavement

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

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

Operating on Public Roads

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

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

Operating at Excessive
Speeds

Operating the 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 experience.

SAFETY

13

SAFETY

Safety Warnings

Physical Control of the Vehicle

Removing a hand from the handlebars or
feet from the footrests during operation can
reduce your ability to control the vehicle or
cause loss of balance and ejection from the
vehicle. If the operator's foot is not firmly
planted on the footrest, it could also contact
the rear wheels.

Never remove your hands from the
handlebars while operating, and always
keep both feet on the footrests.

Turning Improperly

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

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

Never turn abruptly or at sharp angles. Never
turn at high speeds. Practice turning at slow
speeds before attempting to turn at faster
speeds.

Jumps and Stunts

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

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

Improper Hill Climbing

Improper hill climbing could cause loss of
control or overturn. Always follow proper
procedures for climbing hills as described in
the owner's manual. See page 55. Always
move the 4X4 switch to ADC 4X4 (if
equipped) before ascending or descending a hill.

14

SAFETY

Safety Warnings

Descending Hills Improperly

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

• Always follow proper procedures for travel­ing down hills as described in the owner's
manual. NOTE: A special technique is
required when braking while traveling down­hill. See page 57.

• Always descend a hill with the transmission
in forward gear. Do not descend a hill with
the transmission in neutral. Always move the
4X4 switch to ADC 4X4 (if equipped) before
ascending or descending a hill. See page 36.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

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

Crossing Hillsides

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

If crossing a hillside is unavoidable, always follow proper procedures as
described in the owner's manual. See page 56.

Never attempt to turn the vehicle around on any hill until you've mastered the
turning technique (on level ground) as described in the owner's manual. See
page 58.

15

SAFETY

Safety Warnings

Stalling While Climbing a Hill

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

• Always maintain a steady speed when climbing
a hill.

• Always move the 4X4 switch to ADC 4X4 (if
equipped) before ascending or descending a
hill. See page 36.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the service brakes.

• Lock the parking brake when fully stopped.

• Dismount on uphill side, or to either side if the vehicle is pointed straight
uphill.

• Turn the vehicle around and remount, following the procedure described in
the owner's manual. See page 58.

If the vehicle begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards. Apply the service brake
gradually.

• When fully stopped, apply the rear brake as well, and then lock the parking
brake.

• Dismount on uphill side, or to either side if the vehicle is pointed straight
uphill.

• Turn the vehicle around and remount, following the procedure described in
the owner's manual. See page 58.

16

Safety Warnings

Operating on Steep Hills

Operating on excessively steep hills could cause
an overturn.

Never operate on hills too steep for the vehicle or
for your abilities. Never operate the vehicle on hills
steeper than 25 degrees.

Operating on Slippery Terrain

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

Do not operate on excessively rough, slippery or
loose terrain. Always use extra caution on rough,
slippery or loose terrain.

Operating in Unfamiliar Terrain

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

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

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

SAFETY

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 Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.
Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution
and always follow proper operating procedures as outlined in this manual. See
page 60.

Skidding or Sliding

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

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

18

SAFETY

Safety Warnings

Improper Cargo Loading

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

• Never exceed the stated load capacity for

this vehicle.

• Cargo should be properly distributed and

securely attached.

• Reduce speed when carrying cargo or pull-

ing a trailer. Allow a greater distance for
braking.

• Always follow the instructions in the owner's manual for carrying cargo or pull-

ing a trailer.

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 61.

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

Poor Visibility

Operating the 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.

19

SAFETY

Safety Warnings

Operating Through Deep Water

Operating the vehicle through deep or
fast-flowing water could cause the tires to
float, causing loss of control or overturn.

Avoid operating the vehicle through deep
or fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page

59):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.

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

Operating on Frozen Bodies of Water

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

Never operate the vehicle on a frozen body of
water.

20

SAFETY

Safety Warnings

Operating a Damaged Vehicle

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

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical
skills. Persons with cognitive or physical disabilities who operate this vehicle
have an increased risk of overturn and loss of control.

Hot Exhaust Systems

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

Unauthorized Use of the Vehicle

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

21

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

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH
NEVER:

• Operate on public roads. A collision can occur with another vehicle.

• Carry passengers. Passengers affect balance and steering and increase risk
of losing control.

• USE ALCOHOL or DRUGS before or while operating this vehicle.

• Operate at speeds too fast for your skills or the conditions.

• Operate this vehicle on HILLS steeper than 25 degrees. To prevent flipover
on hilly terrain, use throttle and brakes gradually.

ALWAYS:

• Use an approved HELMET AND PROTECTIVE GEAR.

• Avoid paved surfaces. Pavement may seriously affect handling and control.

• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and
rough terrain and in turns.

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

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

PARKING BRAKE may relax when used for more than 5 minutes. When parking
on grades, leave shift in forward.

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

7175784

22

Safety Labels and Locations

+

+

Tire Pressure/Load

Warning

Reverse Override

Warning

+

Front Rack

Warning

+

General

Warning

Tire Pressure/Load Warning

WARNING
Improper tire pressure or overloading can cause loss of control.
Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 7.0 psi (48.3 kPa)
Center: 10.0 psi (68.9 kPa)
Rear: 10.0 psi (68.9 kPa)

• Maximum weight capacity: 1115 lbs. (507 kg)

SAFETY

7175651

Front Rack/Box Warning

WARNING

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

result causing severe injury or death. Tow only from tow hooks or hitch.

• Max. Rack Loads: 100 lbs. (45 kg)

Reverse Override Warning

WARNING
Improper use of override button can lead to loss of control resulting in severe

injury or death. Do not activate override while throttle is engaged. Always apply
throttle gradually, while in reverse.

7175662

7175486

23

SAFETY

+

Clutch Cover

Warning

+

Age 16 Warning

+

Container/No Passenger

Warning

Safety Labels and Locations

Container/No Passenger Warning

WARNING
Remove flammable containers from box before refueling.
WARNING

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

• Never carry passengers.

Maximum Box Load 800 lbs. (363 kg)

7079316

24

SAFETY

Safety Labels and Locations

Age 16 Warning

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

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

7172588

Clutch Cover Warning

WARNING

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

operate vehicle with guard removed.

• Do not modify engine or clutch. Doing so can cause part failure, possible

imbalance, and excessive engine RPM, which can result in serious injury or
death.

NO STEP

7172563

Hitch Capacity Label

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

9921509

25

FEATURES AND CONTROLS

Mode/Reverse

Override

Switch

Main Key Switch

Engine

Stop Switch

Headlight

Switch

4X4

Switch

Switches

Mode/Reverse Override Switch

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

WARNING! Pressing the override button while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before pressing the override button.

The override switch also allows activation of 4X4 in reverse, if the 4X4
switch is on. This switch is also used to toggle through the modes of the
rider information center. See page 37.

All Wheel Drive (AWD) Switch

See page 34 for AWD information.

26

FEATURES AND CONTROLS

OFF OFFRUN

Switches

Engine Stop Switch

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

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

Main Key Switch

Use the main key switch to start the engine. See page 51 for starting pro­cedures.

Headlight Switch

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

27

FEATURES AND CONTROLS

WARNING

Throttle Lever

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

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

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

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

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

28

FEATURES AND CONTROLS

WARNING

WARNING

Brake Systems

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

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

Operating the vehicle with a spongy brake lever can result in loss of braking,
which could cause an accident. Never operate the vehicle with a spongy-feeling
brake lever. Always contact your dealer for service before operating the vehicle.

The braking system is controlled by the two brake levers located on the
handlebars. The service brake (left lever) is an all-wheel brake. Use the
service brake for normal braking. The auxiliary brake (right lever) is a
middle axle rear brake only.

29

FEATURES AND CONTROLS

Brake Systems

Service Brake Lever

Squeeze the service brake lever
(left lever) toward the handlebar to
apply the front and rear brakes.
These brakes are hydraulically acti­vated disc brakes.

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

Auxiliary Brake Lever

Squeeze the auxiliary brake lever (right lever) toward the handlebar to
apply the middle axle (rear brake) only.

Use the auxiliary brakes for addi­tional braking or for backup if the
service brake system fails.

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

30

FEATURES AND CONTROLS

WARNING

Master Cylinders

Indicator Windows

Master Cylinder/Brake Fluid

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

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

The master cylinders are located on the left and right handlebars. Check
the fluid levels of both master cylinders before each use of the vehicle.

1. Position the vehicle on a level surface.

2. Position the handlebars so the master cylinders are level.

3. View the brake fluid level through the indicator window on the top

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

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

31

FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

park.

2. Squeeze and release the brake

lever two or three times, then
squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

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

lever. It will return to its unlocked position.

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

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

32

FEATURES AND CONTROLS

Gear

Selector

Fuel Tank

Cap

Automatic Transmission Gear Selector

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

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

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

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

Always place the transmission in park and lock the parking brake when­ever the vehicle is left unattended.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and
when operating at less than 7 mph (11 km/h) for extended periods of
time.

Fuel Tank Cap

Always refuel with the engine
stopped, and outdoors or in a well
ventilated area. Refuel on a level
surface.

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

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

moving could cause transmission damage.

33

FEATURES AND CONTROLS

4X4

Switch

All Wheel Drive (AWD) System

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

ADC 4X4 Mode (if equipped)

When the switch is on ADC 4X4,
the ADC system allows engine
braking to all six wheels when the
vehicle descends a hill or incline.
Always move the 4X4 switch to
ADC 4X4 before ascending or
descending a hill. See page 36.

AWD Mode

When the switch is on 4X4, the vehicle is in all wheel drive, and the
AWD indicator light in the instrument cluster will be on.

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

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

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

on. See page 26.

2X4 Mode

When the switch is on 2X4, the middle and rear wheels drive at all
times.

34

FEATURES AND CONTROLS

All Wheel Drive System

Engaging AWD

The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable AWD until the
engine RPM is below 3100. Once enabled, AWD remains enabled until
the 4X4 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 4X4 switch before getting into conditions where front wheel
drive may be needed. If the rear wheels are spinning, release the throttle
before switching to AWD.

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

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

35

FEATURES AND CONTROLS

Active Descent Control (ADC) System

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

Engaging Active Descent Control

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

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

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

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

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

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

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

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

36

FEATURES AND CONTROLS

Rider

Information

Center

Speedometer

Needle

Speedometer

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle
speed from the right front wheel. In addition to showing vehicle speed,
the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles as well as hours of
operation. It also includes a reverse speed limiter function that limits the
vehicle's speed to approximately 7-9 mph (11-14 km/h). Refer to page
26 for additional information.

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

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

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

37

FEATURES AND CONTROLS

1

2

345

6

7

9

8

Instrument Cluster

Rider Information Center

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

1. Gear Indicator - This

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

2. 4X4 Indicator - This

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

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

5. Low Battery and 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.

6. Odometer/Tachometer/Tripmeter/ Hour Meter

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

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

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

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

9. Mode Indicator

38

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse
override button is also the MODE button. See page 26. The transmission
cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

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

Hour Meter Mode

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

Tachometer Mode

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

39

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

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

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

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

40

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

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

Gear Circuit Diagnostic Screen

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

Programmable service interval

When the hours of engine operation equal the programmed service
interval setting, the wrench icon will flash for 5 seconds each time the
engine is started. When this feature is enabled, it provides a convenient
reminder to perform routine maintenance. See page 42.

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

41

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

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

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

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

until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

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

1. Enter the diagnostic mode.

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

(MP).

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

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

42

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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

See page 45 for Blink Codes and Failure Descriptions. Use the follow­ing procedure to download blink codes (failure codes) from the EFI
module.

1. Place the transmission in park.

2. Stop the engine.

3. Turn the key switch to the ON position.

4. Turn the key switch off and on three times in less than five seconds,

then leave the switch on. Any blink code numbers stored in the EFI
module will display, one at a time, on the screen. The number “61”
and the word “END” displays after all codes have been transmitted.

43

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Code Definitions

Open Load:

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

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

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

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

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

44

FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink
Code

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

Failure Description

45

OPERATION

WARNING

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

Break-In Period

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

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

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

46

OPERATION

Break-In Period

Engine and Drivetrain Break-in

1. Fill the fuel tank with gasoline. See page 33. Always exercise

extreme caution whenever handling gasoline.

2. Check the engine oil level on the dipstick. See page 72. Add oil if

necessary to maintain the level between the safe and add marks.

3. Drive slowly at first. Select an open area that allows room to famil-

iarize yourself with vehicle operation and handling.

4. Vary the throttle positions. Do not operate at sustained idle.

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

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

6. Pull only light loads.

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

ever comes first.

PVT Break-in (Clutches/Belt)

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

47

OPERATION

Pre-Ride Checklist

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/lever travel Ensure proper operation 29

Brake fluid Ensure proper level 31

Auxiliary brake Ensure proper operation 30

ADC Fluid Ensure proper level 80

Front suspension Inspect, lubricate if necessary 71

Rear suspension Inspect, lubricate if necessary 71

Steering Ensure free operation -

Tires Inspect condition and pressure 87

Wheels/fasteners Inspect, ensure fastener tightness 87

Frame nuts, bolts, fasteners Inspect, ensure tightness -

Fuel and oil Ensure proper levels 33

Coolant level (if applicable) Ensure proper level 82

Coolant hoses (if applicable) Inspect for leaks -

Throttle Ensure proper operation 28

Indicator lights/switches Ensure operation 26

Engine stop switch Ensure proper operation 27

Air filter, pre-filter Inspect, clean 89

Air box sediment tube Drain deposits whenever visible -

Headlamp Check operation, apply Polaris dielec-

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

Dump box latch Check condition and operation of the

Riding gear Wear approved helmet, goggles, and

tric grease when lamp is replaced

tric grease when lamp is replaced

mechanism

protective clothing

84

88

72

83

117

27
91

95

-

8

48

OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

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

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

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

gency situations (if service brakes become inoperable).

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

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

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. Drive in a manner appropriate for your skills and operating condi-

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

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

cle.

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 overturn 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.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

49

OPERATION

Know Your Riding Area/Tread Lightly

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

Help keep our trails open for recreational vehicle use. As an off-road
enthusiast, you represent the sport and can set a good example (or a poor
example) for others to follow. 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

Starting the Engine

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

lated area.

2. Place the transmission in park.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

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

5. Do not press the throttle while starting the engine.

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

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

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

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

NOTICE: Operating the vehicle immediately after starting could cause engine

Cold Weather Operation

If the 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.

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

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

51

OPERATION

Driving Procedures

1. Wear a helmet and eye protection. See page 8.

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

handlebars.

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

4. Shift the transmission into gear.

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

6. Release the parking brake.

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

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

brakes on level surfaces.

52

OPERATION

Turning the Vehicle

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, steer in the direction
of the turn, leaning your
upper body to the inside of
the turn while supporting
your weight on the outer
footrest. This technique
alters the balance of traction
between the rear wheels,
allowing the turn to be made
smoothly. The same leaning
technique should be used for
turning in reverse.

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

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

53

OPERATION

Sideways

skid

Turn in

direction of

skid

Driving on Slippery Surfaces

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

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

2. Slow down when entering slippery areas.

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

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

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

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

quick, sharp turns, which can cause skids.

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

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

54

OPERATION

25° Maximum

Driving Uphill

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

1. Always move the 4X4 switch to ADC 4X4 (if equipped) before

ascending or descending a hill. See page 36.

2. Drive straight uphill.

3. Avoid steep hills (25° maximum).

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

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

6. Keep both feet on the footrests.

7. Shift body weight uphill.

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

throttle suddenly could cause the vehicle to flip over backwards.

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

include quick dismounting of the vehicle.

55

OPERATION

Driving on a Sidehill (Sidehilling)

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

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

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

possible, or dismount on the uphill side immediately!

56

OPERATION

Driving Downhill

When driving downhill, follow these precautions:

1. Always move the 4X4 switch to ADC 4X4 (if equipped) before

ascending or descending a hill. See page 36.

2. Avoid steep hills (25° maximum).

3. Shift body weight uphill.

4. Drive straight downhill.

5. Slow down. Excessive speed when traveling downhill can cause

loss of control.

6. Squeeze the brake lever gradually. Applying the brakes too firmly

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

57

OPERATION

8 ft. (2.4 m)

Turning Around on a Hill (K-Turn)

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

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

2. Always move the 4X4 switch to ADC 4X4 (if equipped) before

ascending or descending a hill. See page 36.

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

4. Dismount on the uphill side of the vehicle, or on the left if the vehi-

cle is pointing straight uphill.

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

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

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

7. Lock the parking brake and remount the vehicle from the uphill

side, keeping body weight uphill.

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

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

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

58

OPERATION

Maximum

Depth

Driving Through Water

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

1. Determine water depths and

current before entering
water.

2. Choose a crossing where

both banks have gradual
inclines.

3. Avoid operating through

deep or fast-flowing water.

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

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

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

• Proceed slowly. Avoid rocks and obstacles.

• Balance your weight carefully. Avoid sudden movements.

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

Do not make sudden throttle changes.

inspected after operation in water. Perform the services outlined in
the maintenance chart. See page 67. The following areas need
special attention: engine oil, transmission oil, demand drive fluid, rear
gearcase oil, and all grease fittings

If the vehicle tips or overturns in water, or if the engine stops during or
after operating in water, restarting can result in serious engine
damage. Transport the vehicle to your dealer for service before
restarting the engine. If this is not possible, follow the vehicle
immersion inspection and drying procedures outlined on page 98,
then see your dealer for service at the first opportunity.

.

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

59

OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

ards such as logs, rocks and low hanging branches.

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

terrain. Not all obstacles are immediately visible.

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

fallen trees.

60

OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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

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

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

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

61

OPERATION

WARNING

Hauling Cargo

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle
handling and may cause loss of control or brake instability, which can result in
serious injury or death. Always follow these precautions 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.

• Reduce speed and allow a greater distance for braking.

• Cargo should be properly distributed and carried as low and forward in the
cargo box as possible.

• Always attach the tow load to the hitch point designated for your vehicle.

• Use extreme caution when applying brakes with a loaded vehicle. Avoid
terrain or situations that may require backing downhill.

• Do not block the front headlight beam when carrying loads on the front rack.

• Do not tow any trailer on a grade steeper than 15°.

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

Maximum Cargo Capacities (Level Ground)

Total Cargo 900 lbs. (408 kg)

Front Rack Cargo 100 lbs. (45 kg)

Cargo Box 800 lbs. (363 kg)

Maximum Towing Capacities

Towed Load (level ground) 1500 lbs. (681 kg)

Towed Load (up to 15° incline) 850 lbs. (386 kg)

Vertical Hitch Weight 150 lbs. (68 kg)

Towing Grade 15°

62

OPERATION

Load cargo as far

forward as possible

Maximum

8.25" (21 cm)

Hauling Cargo

1. Always read and understand the load distribution warning labels on

the vehicle, and never exceed the weight capacities outlined in the
specifications section of the owner's manual and on the safety
labels. The total load (operator, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.

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

3. Always operate the vehicle with extreme caution whenever hauling

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

4. Slow down.

5. The cargo box dump latch must be securely latched before loading

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

6. Always attach a towed load to the hitch point.

NOTICE: Using an improper hitch or exceeding

the maximum tongue weight capacity
can result in serious damage to the
vehicle and will void your vehicle
warranty. Never install a hitch longer
than 8.25" (21 cm). Never install
automotive accessories on your
Polaris vehicle. Always install Polaris­approved (or equivalent) accessories
designed for use on this vehicle.

63

OPERATION

Latch

Release

Levers

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo.

Do not attempt to dump or unload
the vehicle while parked on an
incline.

2. Lock the parking brake.

3. Dismount the vehicle.

4. Check cargo distribution. If cargo

has shifted to the rear of the box,
exercise caution.

WARNING! If the weight distribution in the
box is located toward the rear of the box
when the release lever is pulled forward, the
box may dump on its own, which could cause
serious injury. Never operate the dump lever
without checking the position of the load.
This will prevent unexpected dumping of the
cargo box. Never carry passengers in the
cargo box.

5. Pull the cargo box release lever forward.

6. Lift the front of the cargo box to dump the cargo.

7. Lower the cargo box. Make sure the latch is secure before operating.

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

operate this vehicle with the cargo box in the raised position.

64

OPERATION

Parking on an Incline

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

1. Stop the engine.

2. Place the transmission in park.

3. Lock the parking brake.

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

65

EMISSION CONTROL SYSTEMS

Noise Emission Control System

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

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

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

Operation of off-road vehicles on public lands in the U.S.A. is regulated
by 43 CFR 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 vehicle compliance labels can be found on the frame tubing of the
vehicle.

Electromagnetic Interference

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

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

66

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 134.

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

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

Severe Use Definition

• Frequent immersion in mud, water or sand

• Racing or race-style high RPM use

• Prolonged low speed, heavy load operation

• Extended idle

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

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

67

MAINTENANCE

WARNING

Periodic Maintenance Chart

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

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to severe

use.

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

not void the emissions warranty but may affect emissions.)

 Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item Maintenance Interval

Q

Steering - Pre-Ride - Make adjustments as need

X Front suspension - Pre-Ride -
X Rear suspension - Pre-Ride -

Tires - Pre-Ride -

X Brake fluid level - Pre-Ride -
X Brake lever travel - Pre-Ride -

Brake system - Pre-Ride -

Wheels/fasteners - Pre-Ride -

Frame fasteners - Pre-Ride -

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

X Air box sediment

tube

Coolant
(if applicable)

X ADC fluid (ADC

models)

Headlamp/taillight - Daily - Check operation; apply

(whichever comes first)

Hours Calendar Miles

- Daily - Drain deposits when visible

- Daily - Check level daily, change

- Daily - Check level daily, add as

(Km)

ed. See Pre-Ride Checklist
on page 48.

as needed

coolant every 2 years

needed

dielectric grease if replacing

Remarks

68

Periodic Maintenance Chart

MAINTENANCE

Item Maintenance Interval

XEAir filter,

main element

X

Brake pad wear 10 H Monthly 60 (100) Inspect periodically

Q

X Engine oil change

(break-in)

Battery 20 H Monthly 125 (200) Check terminals; clean; test

Q

ADC fluid 25 H - - Change fluid if extreme use

X Front gearcase

(demand drive) oil

X Middle gearcase

oil (if equipped)

X Rear gearcase oil

(if equipped)

X Transmission oil 25 H Monthly 155 (250) Inspect level; change yearly
XEEngine breather

filter (if equipped)

X General

lubrication

Shift linkage 50 H 6 M 310 (500) Inspect, lubricate, adjust

Q

Steering 50 H 6 M 310 (500) Lubricate

X Front suspension 50 H 6 M 310 (500) Lubricate
X Rear suspension 50 H 6 M 310 (500) Lubricate

Q

Throttle Cable/

E

ETC Switch

(whichever comes first)

Hours Calendar Miles

- Weekly - Inspect; replace as needed

20 H 1 M 125 (200) Perform a break-in oil change

25 H Monthly 155 (250) Inspect level; change yearly

25 H Monthly 155 (250) Inspect level; change yearly

25 H Monthly 155 (250) Inspect level; change yearly

25 H Monthly 155 (250) Inspect; clean if needed

50 H 3 M 310 (500) Lubricate all fittings, pivots,

50 H 6 M 310 (500) Inspect; adjust; lubricate;

(Km)

conditions (see page 80)

cables, etc.

replace if necessary

Remarks

E Throttle Body

Intake Duct

X Front hub bear-

ings (if equipped)

Drive belt 50 H 6 M 310 (500) Inspect; adjust; replace as

Cooling system
(if applicable)

50 H 6 M 310 (500) Inspect duct for proper seal-

50 H 6 M 310 (500) Inspect; clean; replace as

50 H 6 M 620 (1000) Inspect coolant strength

ing/air leaks

needed

needed

seasonally; pressure test
system yearly

69

MAINTENANCE

Periodic Maintenance Chart

Item Maintenance Interval

X Engine oil change 100 H 6 M 620 (1000) Perform a break-in oil change

X Oil filter change 100 H 6 M 620 (1000) Replace with oil change

Q

Valve clearance 100 H 12 M 620 (1000) Inspect; adjust

E

Fuel system 100 H 12 M 620 (1000) Check for leaks at tank cap,

X Radiator (if

applicable)

X Cooling hoses

(if applicable)

X Engine mounts 100 H 12 M 620 (1000) Inspect

Exhaust muffler/
pipe

Q

Spark plug 100 H 12 M 620 (1000) Inspect; replace as needed

E

X Wiring 100 H 12 M 620 (1000) Inspect for wear, routing,

Q Clutches (drive

and driven)

Q Shift selector

lubricant

Q Brake fluid 200 H 24 M 1240 (2000) Change every two years

Q ADC fluid

(ADC models)

X

Fuel filter 200 H 24 M 1240 (2000) Check for leaks around lines.

Q

E

Spark arrestor 300 H 36 M 1860 (3000) Clean out

Q Toe adjustment - Inspect periodically; adjust

XQAuxiliary brake - Inspect daily; adjust as

Headlight aim - Adjust as needed

X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
 Have an authorized Polaris dealer perform these services.

(whichever comes first)

Hours Calendar Miles

100 H 12 M 620 (1000) Inspect; clean external

100 H 12 M 620 (1000) Inspect for leaks

100 H 12 M 620 (1000) Inspect

100 H 12 M 620 (1000) Inspect; clean; replace worn

200 H 24 M 1240 (2000) Inspect; replace as needed

200 H 24 M 1240 (2000) Change every two years;

(Km)

at one month

lines, filter, pump; replace
lines every two years

surfaces

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

parts

every 25 hours if extreme use
conditions (see page 80)

Replace every 2 years, more
often under
extreme conditions.

when parts are replaced

needed

Remarks

70

MAINTENANCE

Front Prop Shaft Yoke

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri­odic Maintenance Chart beginning on page 67. Items not listed in the
chart should be lubricated at the General Lubrication interval.

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

Item Lube Method

Engine Oil PS-4 PLUS Performance

Brake Fluid DOT 4 Only See page 31.

Drive Chains O-ring chain lube or

Gear Selector Oil PS-4 PLUS Performance

Transmission Oil Polaris Premium Synthetic

Front Gearcase
(Demand Drive) Oil

Middle Gearcase Oil Premium ATV Angle Drive

Rear Gearcase Oil See page 78.

ADC Fluid Demand Drive Plus Fluid See page 80.

Front Prop Shaft Yoke Polaris Premium U-Joint

Synthetic 2W-50

SAE 80/90

Synthetic 2W-50

Gearcase Lube

Demand Drive Plus Fluid See page 76.

Fluid (or GL5 80-90 weight
gear lube)

Lube

See page 72.

Lubricate as often as required
(before each ride in wet condi­tions).

Maintain oil level at the center of
the shift rail. Do not overfill.

See page 75.

See page 79.

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

X = Perform more often for vehicles subjected to severe use

71

MAINTENANCE

Dipstick

Safe

Add Oil

{

Safe

Range

Check Level

on Top Side

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn­thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to
be changed more frequently if Polaris oil is not used. Always use 2W-50
oil. Follow the manufacturer's recommendations for ambient tempera­ture operation. See page 124 for the part numbers of Polaris products.

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

Oil Level

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

1. Position the vehicle on a level

2. Lift the lever lock to remove

3. Reinstall the dipstick com-

4. Remove the dipstick and check

Tip: Due to the dipstick entry angle into

5. After reinstalling the dipstick,

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

surface.

the dipstick. Wipe it dry with a
clean cloth.

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

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

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

seat the lever lock.

72

MAINTENANCE

Drain Plug Location

to front

Engine Oil

Oil and Filter Change

Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 67. Always change the oil filter
whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine.

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

3. Clean the area around

the drain plug.

4. Place a drain pan

under the crankcase.

5. Remove the drain

plug. Allow the oil to
drain completely.

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

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

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

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

8. Place shop towels beneath the oil

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

9. Using a clean dry cloth, clean the

filter sealing surface on the
crankcase.

73

MAINTENANCE

Engine Oil

Oil and Filter Change

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

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

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

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

12. Remove the dipstick.

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

14. Place the transmission in park.

15. Lock the parking brake.

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

17. Stop the engine.

18. Check for leaks.

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

mark on the dipstick.

20. Dispose of used filter and oil properly.

74

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Transmission Oil

Always check and change the
transmission oil at the intervals
outlined in the Periodic Mainte­nance Chart beginning on page 67.
Maintain the oil level at the bottom
of the fill plug hole. The fill plug is
located on the right side of the
ATV behind the footwell. The
drain plug is located on the bottom
left side of the gearcase.

We recommend the use of Polaris
Premium AGL Synthetic Gearcase
Lubricant. See page 124 for the
part numbers of Polaris products.

Access the transmission fill plug from the right side of the vehicle.
Access the drain plug from the left side of the vehicle.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the footwell (see page 86).

3. Remove the fill plug. Check the oil level.

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

5. Reinstall the footwell.

Oil Change

1. Remove the footwell (see page 86).

2. Place a drain pan under the gearcase. Remove the drain plug. Allow

the oil to drain completely.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Remove the fill plug. Add 15 oz. (450 ml) of the recommended oil.

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

6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

75

MAINTENANCE

Drain Plug

Fill Plug

Fill Level

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out­lined in the Periodic Maintenance Chart beginning on page 67. We rec­ommend the use of Polaris Demand Drive Plus Fluid. Use of other
fluids may result in improper operation of components. See page 124 for
the part numbers of Polaris products.

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

Demand Drive Capacities

Demand Drive with ADC 9.3 oz. (275 ml)

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

Fluid Check

1. Position the vehicle on a

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

2. Add the recommended

fluid as needed to bring
the level to the bottom of
the fill hole threads.

3. Reinstall the fill plug.

Torque to 8-10 ft. lbs.
(11-14 Nm).

76

MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

1. Position the vehicle on a level surface. Remove the fill plug.

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

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

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

5. Add the recommended fluid.

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

7. Check for leaks.

8. Dispose of used fluid properly.

77

MAINTENANCE

Drain Plug

Fill Plug

Rear Gearcase Oil

Always check and change the rear
gearcase oil at the intervals outlined in
the Periodic Maintenance Chart
beginning on page 67. Maintain the
fluid level at the bottom of the fill
hole threads. The oil capacity is 5 oz.
(150 ml). Do not overfill.

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

We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80­90 weight gear lube). See page 124 for the part numbers of Polaris prod­ucts.

Oil Check

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed to bring the level to the bottom

of the fill hole threads. Do not overfill.

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

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain hole.

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

4. Clean and reinstall the drain plug with a new sealing washer. Torque

to 14 ft. lbs. (19 Nm).

5. Remove the fill plug. Add 5 oz. (150 ml) of the recommended oil.

Do not overfill.

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

7. Check for leaks.

8. Dispose of used oil properly.

78

MAINTENANCE

Drain Plug

Check/Fill Plug

Middle Gearcase Oil

Always check and change the mid­dle gearcase oil at the intervals
outlined in the Periodic Mainte­nance Chart beginning on page 67.

We recommend the use of Polaris
ATV Angle Drive Fluid (or GL5
80-90 weight gear lube). See page
124 for the part numbers of Polaris
products.

The middle gearcase fill plug is
located on the side of the gearcase.
Maintain the oil level even with
the bottom thread of the fill plug
hole.

Oil Check

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

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

Oil Change

1. Remove the fill plug.

2. Remove the drain plug from the bottom of the gearcase. Drain the

oil into a drain pan. Discard used oil properly.

3. Clean and reinstall the drain plug. Torque to 14 ft. lbs. (19 Nm).

4. Add 17 oz. (500 ml) the recommended fluid.

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

6. Check for leaks

79

MAINTENANCE

ADC Fluid Reservoir

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two
fluid levels that must be maintained (demand drive fluid and ADC
fluid). See page 76 for demand drive fluid maintenance.

Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 67. Maintain the fluid
level between the minimum and maximum marks on the reservoir. We
recommend the use of Polaris Demand Drive Plus Fluid. See page 124
for the part numbers of Polaris products.

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

1. Open the front box cover and pull

2. View the fluid level in the reservoir.

3. If the level is below the minimum

4. Reinstall the cap. Secure the access

the hydraulic system.

open the access door.

mark, remove the cap and add the
recommended fluid.

door. Secure the box cover.

80

MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

1. Position the vehicle on a level surface. Before performing the fluid

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

2. Thoroughly clean the areas around and on the ADC reservoir and

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

3. Remove the reservoir cap and diaphragm assembly. Use a shop

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

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

5. Remove the protective caps from the bleeder valves.

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

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

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

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

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

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

9. Reinstall the cap securely.

10. Clean up any drips or spills.

81

MAINTENANCE

Cooling System

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

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

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

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool­ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/
coolant and distilled water. Polaris Premium 60/40 is already premixed
and ready to use. Do not dilute with water. See page 124 for the part
numbers of Polaris products.

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

Recovery Bottle Coolant

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

1. Remove the left side panel.

See page 86.

2. Maintain the coolant level

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

3. Add coolant as needed.

82

MAINTENANCE

Radiator Cap

Cooling System

Radiator Coolant

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

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

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

1. Open the front box cover and

pull open the access door.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radiator
filler neck.

4. Reinstall the pressure cap. Use

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

5. Secure the access door.

6. Secure the box cover.

83

MAINTENANCE

3/64" (1 mm)

Brakes

Front/Rear/Middle Brakes

The front, rear and middle brakes are hydraulic disc brakes. These
brakes are self-adjusting.

Under normal operation, the diaphragm extends into the reservoir as
fluid level drops. If the fluid level is low and the diaphragm is not
extended, a leak is likely and the diaphragm should be replaced. To
ensure proper diaphragm operation, always fill the reservoir as needed
whenever the cover is loosened or removed. Do not overfill.

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

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

1. Always keep brake fluid at an adequate

level. See page 31.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

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

5. Check the security and surface condition

of the disc.

84

MAINTENANCE

String

Stand

2

1

Toe Alignment

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

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

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

3. Tie a length of string between

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

4. Measure the distance from

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

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

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

vice.

85

MAINTENANCE

Step 1 Step 2 Step 3

Screws

Rivets

Steering Assembly

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

Side Panel Removal

1. Remove the seat.

2. Grasp the rear of the side panel near the rear cab. With a firm

motion, pull the panel outward to disengage the side panel from the
grommet. Pull the panel downward and rearward to remove it.

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

secure them.

Footwell Removal

1. Remove the four screws on

the bottom of the footwell.

2. Use a flat screwdriver or

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

3. Remove the footwell.

86

MAINTENANCE

WARNING

1/8" (3 mm)

Tires

Operating your vehicle with worn tires, improperly inflated tires, non-standard
tires or improperly installed tires will affect vehicle handling and could cause an
accident resulting in serious injury or death. Always follow all tire maintenance
procedures as outlined in this manual and on the labels on the vehicle. Always
use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 122 for recom­mended tire type, size and pressure.

Tire Tread Depth

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

Front Wheel Hub Tightening

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

Wheel Removal

1. Stop the engine.

2. Place the transmission in park.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

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

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

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

87

MAINTENANCE

Cast Aluminum Steel

90 ft. lbs.
(122 Nm)

27 ft. lbs.

(37 Nm)

Tires

Wheel Installation

1. Place the transmission in park.

2. Lock the parking brake.

3. Place the wheel on the hub with the valve stem toward the outside

and rotation arrows on the tire pointing toward forward rotation.

4. Install the wheel nuts and finger-tighten them.

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

WARNING! Loose nuts could cause a tire to come off during operation, which
could result in an accident or overturn. Always ensure that all nuts are torqued to
specification.

Wheel Nut Torque Specifications

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

Nut Type Nut Torque

Lug Nut 90 ft. lbs. (122 Nm)

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

88

Air Filter

Main Filter

Pre-Filter

1. Remove the seat.

2. Release the air box cover clips,

and remove the air box cover.

3. Loosen the clamp and remove

the filter.

4. Remove the fabric type pre-filter

from the main filter. Wash the
pre-filter in soapy water, then
rinse and let dry.

5. Reinstall the pre-filter over the

main filter. Install a new main
filter if needed.

6. Reinstall the filter into the air

box and tighten the clamp. Do
not over-tighten the clamp, as
filter damage could occur.

7. Reinstall the air box cover and

the seat.

MAINTENANCE

89

MAINTENANCE

Fuse Panel

Fuses

5or61520 20

Fuse Replacement

Fuse Feature Supported

5A Speedometer

15A Electronic Fuel Injection

20A (Main Fuse) Ignition, Lighting

20A Accessories, 12V Power Receptacle

If the engine stops or will not start,
or if you experience other electrical
failures, a fuse may need replace­ment. Locate and correct any short
circuits that may have caused the
blown fuse, then replace the fuse.
Spare fuses are provided in a com­partment on the top of the access
door.

1. Open the front box cover and

pull open the access door.

2. Remove the suspect fuse from

the fuse panel. If the fuse is
blown, install a new fuse with
the same amperage.

3. Secure the access door.

4. Secure the box cover.

90

MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight
and taillight lenses become dirty during normal operation. Clean lights
frequently and replace burned out lamps promptly. Always make sure
lights are adjusted properly for best visibility.

Upper Headlight Lamp Replacement

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

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

pod.

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

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

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

the speedometer.

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

5. Unplug the headlamp from the wiring harness. Be sure to pull on the

connector, not on the wiring.

6. Turn the lamp counter-clockwise to remove it.

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

sure the tab on the lamp locates properly in the housing.

8. Reassemble the pod.

91

MAINTENANCE

25 ft.

(7.6 m)

2" (5 cm)

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use
the following procedure to make the adjustment.

1. Position the vehicle on a level surface with the headlight approxi-

mately 25 ft. (7.6 m) from a wall. Place the transmission in park.

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

and make a mark on the wall at the same height.

3. Start the engine. Turn the headlight switch to high beam.

4. Observe the headlight aim on the wall. The most intense part of the

headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.

5. The adjustment knob is located on the right side of the headlight

pod. Adjust the beam to the desired position by turning the knob
either clockwise or counter-clockwise.

92

Lights

Phillips Screw

Low Beam Adjustment

The low beam can be adjusted
slightly upward or downward.

1. Loosen the phillips screw located

at the rear of the headlamp.

2. Tilt the headlamp upward or

downward.

3. Tighten the screw.

MAINTENANCE

93

MAINTENANCE

5 1/8"

(13 cm)

Lights

Headlight Housing Replacement

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

pod.

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

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

the speedometer.

4. Unplug the headlamp from the wiring harness.

5. Use a small screwdriver to remove the o-rings from the headlight

mounting tabs.

6. Pull the headlight housing up to release it from the locking tabs.

7. Lift the adjusting knob up to remove it from the locking tabs.

8. Carefully pull the assembly up

and out of the pod.

9. Reverse the steps to install the

new housing and reassemble
the pod. The distance from the
headlamp parting line to the
end of the adjustment knob
stop is 5 1/8" (13 cm).

10. Adjust the headlight aim by

turning the adjusting knob.

94

MAINTENANCE

Harness

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight

harness counter-clockwise and
pull the harness assembly away
from the headlight assembly.

2. Remove the headlamp and install

the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

1. Remove the taillight lens cover mounting screws. Remove the lens

cover and gasket and set aside for reassembly.

2. Remove the lamp.

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

4. Test the light for proper operation.

5. Reinstall the gasket and lens cover.

95

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 122 for the recom­mended spark plug type and gap for your vehicle. Torque spark plugs to
specification.

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

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark
plug firing end condition after the engine has been warmed up and the
vehicle has been driven at higher speeds. Immediately check the spark
plugs for correct color. See page 97.

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

1. Rotate the spark plug cap 1/4 turn and pull it off the spark plug.

2. Using the special wrench provided in the tool pouch, rotate the

3. Reverse the procedure for spark plug installation. Torque to specifi-

damage. Always use Polaris-recommended spark plugs.

Plug Condition Torque Specification

New Spark Plug 9-11 ft. lbs. (12-15 Nm)

Previously Installed Spark Plug 17-20 ft. lbs. (23-27 Nm)

spark plug counter-clockwise to remove it.

cation.

96