Polaris Sportsman Touring 570, Sportsman Touring 570 EPS, Sportsman Touring 570 SP Owner's Manual For Maintenance And Safety

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Read this manual carefully. It contains important safety information.
Operation is prohibited for those under 16 years of age.
Sportsman Touring 570
Sportsman Touring 570 SP
Owner's Manual
for Maintenance and Safety
This is an adult vehicle only.
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A card containing important ATV safety information should be
attached to the owner's manual on the next page.
If you cannot locate this card, or if it has been removed,
please call 1-800-342-3764 for assistance.
WARNING
The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects
or other reproductive harm.
For videos and more information
about a safe riding experience with
your Polaris vehicle, scan this QR
code with your smartphone.
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WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
RANGER® utility vehicles
•RZR® sport vehicles
• VICTORY® motorcycles
• GEM® vehicles We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your POLARIS vehicle.
For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner’s manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer® (MSD) technician.
Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.
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POLARIS® and SPORTSMAN® are trademarks of POLARIS Industries Inc. Copyright 2014 POLARIS Industries 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 mino r discrepancies may result between the actual vehicl e and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions.
Printed in U.S.A. 2015 SPORTSMAN Touring 570/570 EPS/570 SP Owner’s Manual P/N 9925904
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls. . . . . . . . . . . . . . . . . . . 26
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Emission Control Systems . . . . . . . . . . . . . . . 85
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 138
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 142
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 144
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 153
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
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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.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard.
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INTRODUCTION
Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death. A POLARIS ATV is not a toy and can be hazardous to operate. This vehicle handles differently than other vehicles, such as motorcycles and cars. A collision or rollover can occur quickly, even during routine maneuvers like turning, or driving on hills or over obstacles, if you fail to take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and operating procedures before operating a POLARIS ATV. Keep this manual with the ATV.
• Never operate an ATV without proper instruction. Take a certified ATV safety training course (www.atvsafety.org).
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this manual and all product labels and has completed a certified safety training course (www.atvsafety.org).
European Vibration and Noise
The driver-perceived noise and hand/arm and whole body vibration levels of this machinery is measured per prEN 15997.
The operating conditions of the machinery during testing: The vehicles were in like-new condition. The environment was
controlled as indicated by the test procedure(s). The uncertainty of vibration exposure measurement is dependent on
many factors, including:
• Instrument and calibration uncertainty
• Variations in the machine such as wear of components
• Variation of machine operators such as experience or physique
• Ability of the worker to reproduce typical work during measurements
• Environmental factors such as ambient noise or temperature
WARNING
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INTRODUCTION
Vehicle Identification Numbers
Record your vehicle's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a POLARIS key blank (using your key number) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
Engine Serial
Number
Key
Number
VIN
(front or rear frame)
####
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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 information about the authorized ATV RiderCourse
sm
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 in the ATV RiderCourse
sm
for a fee. Call ATV Enrollment
Express at (800) 887-2887 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.
A POLARIS ATV is an off-road vehicle. Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area.
W e strongly advise you to strictly follow the recommended maintenance program outlined in your owner's manual. This preventive maintenance program is designed to ensure that all critical components on your vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMAT ION 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.
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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective clothing for comfort and to reduce the chance of injury.
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of Transportati on (DOT) label.
Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.
Helmet
Eye Protection
Gloves
Boots
Long Pants
Long Sleeves
E
4
051039
0006.31
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SAFETY
Safe Riding Gear
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a POLARIS vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. POLARIS recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.
Gloves
Off-road style gloves with knuckle pads are the best for comfort and protection.
Boots
The best footwear is a pair of sturdy over-the-calf boots with low heels.
Clothing
Always wear long sleeves and long pants to protect arms and legs. Riding pants with kneepads and a jersey with shoulder pads provide the best protection.
Equipment Modifications
We strongly recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle, or make any other modifications to the vehicle for these purposes.
The warranty on your POLARIS ATV is terminated if 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.
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SAFETY
Safety Warnings
Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Heed all safety warnings outlined in this section of the owner’s manual. See the OPERATION section of the owner’s manual for proper operati ng procedures.
Operating Without Instruction
Operating this ATV without proper instruction increases the risk of an accident. The operator must understand how to operate the ATV properly in different situations and on different types of terrain.
Beginning and inexperienced operators should complete the recommended safety training before operating this vehicle. See page 7.
Never permit a guest to operate the A TV unless the guest has read this manual and all product labels and has completed a certified safety training course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone under 16 years of age. Never allow anyone under 12 years of age to ride as a passenger on this 2-up ATV.
Even though a child may be within the recommended age group for operating some A TVs, he/she may not have the skills, abilities, or judgment needed to operate or ride on this ATV safely and could be susceptible to accident or injury.
WARNING
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SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe operating condition before operating increase s the risk of an accident.
Always inspect the ATV before each use to make sure it's in safe operating condition.
Always follow all inspection and maintenance procedures and schedules described in the owner's manual.
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SAFETY
Safety Warnings
Protective Apparel
Riding in this vehicle without wearing an approved helmet and protective eye wear 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 ATV after consuming alcohol or drugs could adversely affect operator judgment, reaction time, balance and perception.
Never consume alcohol or drugs before or while operating an ATV.
Carrying a Passenger
Do not carry a passenger until you have at least two hours of driving experience with this vehicle. See page 57.
Carrying More Than One Passenger
Carrying more than one passenger greatly reduces the operator's ability to balance and control the ATV, which may result in an accident or rollover.
Never carry more than one passenger on this 2-up ATV.
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SAFETY
Safety Warnings
Operating on Pavement
Operating an ATV on paved surfaces (including sidewalks, paths, parking lots and driveways) may adversely affect the handling of the ATV and could result in loss of control and accident or rollover.
Avoid operating the ATV on pavement. ATV tires are designed for off-road use. If it's unavoidable, travel slowly and avoid sudden turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads or highways could result in a collision with another vehicle.
Never operate the A TV on any public street, road or highway, including dirt and gravel roads. In many states it's unlawful to operate ATVs on public streets, roads and highways.
Operating at Excessive Speeds
Operating the ATV at excessive speeds increases the operator's risk of losing control.
Never operate at excessive speeds. Travel at speeds appropriate for your skills, your passenger's skills, and operating conditions.
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SAFETY
Safety Warnings
Physical Control of the ATV
Removing even one hand from the handlebars or one foot from the footrest can reduce ability to control the vehicle or could cause loss of balance and ejection from the ATV.
If a person's feet are not firmly planted on the footrests, they could come into contact with the wheels or other moving parts and lead to accident or injury.
Always keep both hands on the handlebars and both feet on the footrests of the ATV during operation. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator.
Turning Improperly
Turning improperly could cause loss of traction, loss of control, accident or rollover.
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 rollover.
Never attempt wheelies, jumps, or other stunts. Avoid exhibition driving.
Improper Hill Climbing
• Improper hill climbing could cause loss of control or rollover. Always follow proper procedures for climbing hills as described in the owner's manual. See page 61. Always move the 4X4 switch to ADC 4X4 (if equipped) before ascending or descending a hill. See page 37.
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SAFETY
Safety Warnings
Descending Hills Improperly
Improperly descending a hill could cause loss of control or rollover.
• Always follow proper procedures for traveling
down hills as described in the owner's manual. NOTE: A special technique is required when braking while traveling downhill. See page 63.
• 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 37.
• 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 rollover. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a hillside is unavoidable, always follow proper procedures as described in the owner's manual. See page 62.
Never attempt to turn the ATV around on any hill until you've mastered the turning technique (on level ground) as described in the owner's manual. See page 64.
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SAFETY
Safety Warnings
Stalling While Climbing a Hill
Stalling, rolling backwards or improperl y dismounting while climbing a hill could cause a rollover.
• 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 37.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A passenger should also lean uphill.
• Appl y the brakes.
• Lock the parking brake when fully stopped.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. Have a passenger dismount first, then the operator may dismount.
• Turn the ATV around and remount, following the procedure de scribed in the owner's manual. See page 64.
If the ATV begins rolling downhill:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards. Apply the single-lever brake gradually.
• When fu lly stopped, apply the rear brake as well, and then lock the parking brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is pointing straight uphill. Have a passenger dismount first, then the operator may dismount.
• Turn the ATV around and remount, following the procedure de scribed in the owner's manual. See page 64.
Operating on Steep Hills
Operating on excessively steep hills could cause a rollover.
Never operate on hills too steep for the ATV or for your abilities. Never operate the ATV on hills steeper than 15 degrees.
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SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating on excessively rough, slippery or loose terrain could cause loss of traction, loss of control, accident or rollover.
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 rollover.
Unfamiliar terrain may contain hidden rocks, bumps, or holes that could cause loss of control or rollover.
Travel slowly and use extra caution when operating on unfamiliar terrain. Always be alert to changing terrain conditions.
Operating Improperly in Reverse
Improperly operating in reverse could result in a collision with an obstacle or person. Always follow proper operating procedures as outlined in this manual. See page 68.
Before shifting into reverse gear, always check for obstacles or people behind the A TV . When it's safe to proceed, back slowly.
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SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this ATV with improper tires or with improper or uneven tire pressure
could cause loss of control or accident. Always use the size and type of tires
specified for your ATV. Always maintain proper tire pressure as
described in the owner's manual and on safety labels.
Operating Over Obstacles
Improperly operating over obstacles could cause loss of control or rollover.
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 72.
Skidding or Sliding
Skidding or sliding can cause loss of control or rollover (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.
Operating a Damaged ATV
Operating a damaged ATV can result in an accident. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage, including (but not limited to) brakes, throttle and steering systems.
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SAFETY
Safety Warnings
Operating Through Deep Water
Operating the ATV through deep or fast­flowing water could cause the tires to float, causing loss of control or rollover.
Avoid operating the A TV through deep or fast-flowing water. If it's unavoidable to enter water that exceeds the recommended maximum depth (see page 66):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward
motion. Do not make sudden turns or stops, and do not make sudden throttle changes.
• Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving slowly. The friction will help dry out the pads.
Improper Cargo Loading
Overloading the ATV or carrying/towing cargo improperly may cause changes in handling, which could cause loss of control or an accident.
• Never exceed the stated load capacity for
this ATV.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or
pulling a trailer. Allow a greater distance for braking.
• NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs.
(34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
• Always follow the instructions in the owner's manual for carrying cargo or
pulling a trailer. See page 70.
• Alwa ys follow the instructions in the owner's manual for operating with a
passenger. See page 57.
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SAFETY
Safety Warnings
Operating on Frozen Bodies of Water
Operating on frozen bodies of water may result in serious injury or death if the ATV and/or riders fall through the ice.
Never operate the A TV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party. Variances in snow depth and/or water currents may result in uneven ice thickness. Always check with local authorities and residents to confirm ice conditions and thickness over your entire route. ATV operators assume all risk associated with ice conditions on frozen bodies of water.
Poor Visibility
Operating the A TV in darkness or inclement weather could result in a collision or accident, especially if operating on a road or street. This ATV is not equipped with highway-approved lights. Operate this vehicle off-road only. Use caution and drive at reduced speeds in conditions of reduced visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
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 rollover and loss of control. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle. Hot components can cause burns and fire. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle, which could result in an accident or rollover. Always remove the ignition key when the vehicle is not in use.
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SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection. Read and follow the instructions on each label carefully. If any of the labels shown in this manual differ from the labels on your vehicle, always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label.
General Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR DRIVER AND PASSENGER
NEVER USE ON PUBLIC ROADS NEVER CARRY MORE THAN 1 PASSENGER NEVER USE WITH DRUGS OR ALCOHOL NEVER operate:
• without proper ATV training or instruction
• at speeds too fast for your skills or the
conditions
• on public roads - a collision can occur with
another vehicle
• with a passenger unless passenger seat is securely in place THE OPERATOR MUST ALWAYS:
• use proper riding techniques to avoid overturns on hills and rough terrain and
in turns
• avoid paved surfaces - pavement may seriously affect handling and control
• reduce speed and use extra caution at all times when carrying a passenger -
dismount passenger when conditions require
• make sure passenger reads and understands this label and passenger safety
label LOCATE AND READ OPERATOR’S MANUAL. FOLLOW ALL INSTRUCTIONS AND WARNINGS.
7175844
General
Warning
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SAFETY
Safety Labels and Locations
Age 16 Warning
WARNING
Operating this ATV if you are under the age of 16 increases the chances of severe injury or death to both operator and passenger.
NEVER operate this ATV if you are under age 16.
7175375
Reverse Override Warning
WARNING
Improper use of override button can lead to loss of control resulting in serious injury or death. Do not activate override while throttle is engaged. Always apply throttle gradually while in reverse.
7175486
4X4 (AWD) Warning
WARNING
Do not push switch to engage 4X4 (AWD) if the rear wheels are spinning. This may cause severe drive shaft and clutch damage.
7175485
4X4 (AWD)
Warning
Reverse Override
Warning
Age 16
Warning
General Warning
Passenger
Warning
Discretionary
Warning
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SAFETY
Safety Labels and Locations
Passenger Warning/Discretionary Warning
WARNING
PASSENGER SAFETY To reduce the risk of SEVERE INJURY or DEATH NEVER CARRY MORE THAN ONE PASSENGER NEVER RIDE AFTER USING DRUGS OR ALCOHOL NEVER carry a passenger too small to firmly plant feet on footrests and securely
grasp hand holds. THE PASSENGER MUST ALWAYS:
• use an approved helmet and protective gear
• secure ly gras p hand holds and plant feet firmly on footrests while seated in
the passenger seat
• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require
WARNING
• Never operate th is ATV on HILLS steeper than 15 degrees 15°. To
prevent overturn on hilly terrain, use throttle and brakes gradually, and shift
weight uphill.
• REVERSE operatio n can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
7175845
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SAFETY
Safety Labels and Locations
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading can cause loss of control. Loss of control can result in severe injury or death.
• Cold tire pressure: Front: 5.0 psi (34.5 kPa) Rear: 5.0 psi (34.5 kPa)
• Maximum weight capacity: 485 lbs. (220 kg)
• NEVER exceed 50 MPH (80 km/h) when
rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
• NEVER exceed 50 MPH (80 km/h) while
carrying a passenger.
7177982
Rack Warning
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may result causing severe injury or death. Tow only from tow hooks or hitch. Maximum Rack Loads: Front 90 lbs. (41 kg) Rear 180 lbs. (82 kg)
7172572
Tire Pressure /Load
Warning
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SAFETY
Safety Labels and Locations
Clutch Cover Warning
WARNING
• Moving parts hazard under belt-clutch guard. T o prevent serious injury, do not operate vehicle with guard removed.
• Do not modify engine or clutch. Doing so can cause part failure, possible imbalance, and excessive engine RPM, which can result in serious injury or death.
7180089
Hitch Capacity Label (570/570 EPS)
TRAILER MAX WEIGHT: 1225 LBS. (557 KG) ON LEVEL GROUND HITCH MAX. VERTICAL WEIGHT: 120 LBS. (55 KG)
7174159
Hitch Capacity Label (570 SP)
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)
7170509
Rack
Warning
Clutch Cover
Warning
Hitch
Capacity
Label
Rack
Warning
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FEATURES AND CONTROLS
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 is also used to toggle through the modes of the rider information center. See page 38.
Tip: The override switch will not function as a MODE switch if the transmission
is in reverse.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4 (if equipped), 4X4 or 2X4. See page 35.
2x4
Mode/Reverse
Override Switch
Main Key Switch
Engine
Stop Switch
Headlight
Switch
4X4 Switch
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FEATURES AND CONTROLS
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 55 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.
OFF OFFRUN
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FEATURES AND CONTROLS
Throttle Lever
Operating an ATV with sticking or improperly operating throttle controls could cause an accident. Never start or operate an ATV that has a sticking or improperly operating throttle. Always contact your dealer for service before operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in an accident if the throttle lever sticks during operation. Always check the lever for free movement and return before starting the engine. Also check occasionally during operation.
Modifications to the throttle release switch could result in failure to perform as designed, which could result in an accident. Do not attempt to modify the throttle release switch or replace it with any after market throttle mechanisms. Always ensure that the throttle cable is installed and properly routed to the throttle release switch.
Engine speed and vehicle movement are controlled by pressing the throttle lever. The throttle lever is spring loaded. Engine speed returns to idle when the lever is released.
This ATV is equipped with a throttle release switch, which is designed to reduce the risk of a frozen or stuck throttle. If the throttle cable should stick in an open position when the operator releases the throttle lever, engine speed will be limited to idle speed.
WARNING
2x4
Page 31
29
FEATURES AND CONTROLS
Brake Lever
Operating the A TV with a spongy brake lever can result in loss of braking, which could cause an accident. Never operate the ATV with a spongy-feeling brake lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the handlebar to apply the front and rear brakes. These brakes are hydraulically activated disc type brakes that are activated by only one lever.
Always test brake lever travel and master cylinder fluid level before riding. When squeezed, the lever should feel firm. Any sponginess would indicate a possible fluid leak or low master cylinder fluid level, which must be corrected before riding. Contact your dealer for proper diagnosis and repairs.
WARNING
Page 32
30
FEATURES AND CONTROLS
Master Cylinder/Brake Fluid
An over-full master cylinder may cause brake drag or brake lock-up, which could result in an accident. Maintain brake fluid at the recommended level. Do not overfill.
Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of brake failure, which could result in an accident. After opening a bottle of brake fluid, always discard any unused portion.
Check the brake fluid in the master cylinder before each ride.
1. Position the ATV on a level surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window on the top of the master cylinder. The eye will appear dark when the fluid level is full. When fluid is low, the eye will be clear.
4. If the fluid level is low add DOT 4 brake fluid only. Do not overfill.
WARNING
Master
Cylinder
Indicator
Window
Page 33
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 ATV while the parking brake is engaged could result in an accident or fire. Always check to be sure the parking brake is disengaged before operating.
The parking brake may relax if left on for a long period of time. Always block the wheels to prevent rolling. Always block the wheels on the downhill side of the ATV if leaving it parked on a hill. Another option is to park the ATV in a sidehill position. Never depend on the parking brake alone if the ATV is parked on a hill. Always block the wheels to prevent rolling.
Page 34
32
FEATURES AND CONTROLS
Auxiliary Foot Brake
Never back down a hill. Applying the auxiliary brake when backing down a hill may cause rear tipover, which could result in serious injury or death.
Use caution when applying the auxiliary brake. Do not aggressively apply the auxiliary brake when going forward. The rear wheels may skid and slide sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the main brake system. Should the main system fail, use the auxiliary foot brake. Since this is a rear brake only, it will not be as effective as the all wheel single lever system.
The auxiliary foot brake is located on the inside of the right footrest. Operate this brake with your right foot.
If the rear wheels slide while using the auxiliary brake, reduce brake pedal pressure to brake the rear wheels without skidding.
Brake Fluid Level
Check the brake fluid level frequently for the auxiliary brake system. The reservoir is located under the seat on the left side of the vehicle. Maintain the fluid level between the maximum and minimum marks.
WARNING
Auxiliary Foot
Brake
Foot Brake Fluid
Reservoir
Page 35
33
FEATURES AND CONTROLS
Electronic Power Steering (EPS)
Electronic power steering (EPS), if equipped, engages when the ignition key is turned to the ON position. EPS remains engaged whether the vehicle is moving or idle. See page 39 for EPS Warning Indicator infor­mation.
Fuel Tank Cap
This vehicle is equipped with a digital fuel gauge that will indicate a low fuel condition. Refuel when the gauge indicates a low fuel condition.
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 per cent, such as E-85 fuel.
Passenger Seat Backrest
The passenger backrest can be adjusted vertically.
1. Unzip the two zippers at the bottom of the backrest pad. Lift the pad upward to remove it from the backrest frame.
2. To adjust the backrest upward or
downward, loosen the four vertical adjustment screws on the front side of the backrest frame. Slide the backrest upward or downward to the desired position and tighten the screws.
3. Reinstall the backrest pad.
Fuel Tank Cap
Page 36
34
FEATURES AND CONTROLS
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
moving could cause transmission damage.
Whenever the ATV is left unattended, always place the transmission in PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed.
Extreme Use Battery
An optional extreme use battery may be available for your model. If the performance of the factory-installed battery is inadequate due to opera­tion in extreme cold or due to extended use of multiple electrical acces­sories, please see your POLARIS dealer . Ask your dealer to provide any installation procedures that may differ for an extreme use battery.
Gear
Selector
Page 37
35
FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system is controlled by the 4X4 switch.
ADC 4X4 Mode (if equipped)
When the switch is on ADC 4X4, the ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill. See page 37.
4X4 Mode
When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator icon in the instrument cluster display will be visible.
When in 4X4, the demand drive unit will automatically engage any time the rear wheels lose traction. When the rear wheels regain traction, the demand drive unit will automatically disengage.
There is no limit to the length of time the vehicle may remain in 4X4. The vehicle automatically engages 4X4 when operating in reverse if the switch is set to the 4X4 position.
2X4 Mode
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
2x4
4X4
Switch
ADC 4X4 (if equipped)
Page 38
36
FEATURES AND CONTROLS
All Wheel Drive System
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving. Initially, the vehicle's electronic system will not enable 4X4 until the engine RPM is below 3100. Once enabled, 4X4 remains enabled until the 4X4 switch is turned off. If the switch is turned 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 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 (if equipped) while the rear wheels are
spinning may cause severe drive shaft and gearcase damage. Always switch to 4X4 or ADC 4X4 (if equipped) while the rear wheels have traction or are at rest.
Page 39
37
FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the vehicle descends a hill or incline. Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the following conditions occur:
• The 4X4 switch must be in the ADC 4X4 position
• Vehicle speed must be 15 mph (25 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 (25 km/h)
• The throttle is open (throttle is applied)
• The transmission is shifted to neutral or park
Page 40
38
FEATURES AND CONTROLS
Instrument Cluster
NOTICE: High water pressure may damage A T V components. Wash the ATV
by hand or with a garden hose using mild soap. Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Do not allow insect sprays to contact the lens. Immediately clean off any gasoline that splashes on the instrument cluster.
Digital/Analog Gauge
Speedometer
The speedometer displays vehicle speed in either miles per hour (MPH) or kilometers per hour (km/h).
Rider Information
Center
Speedometer
Indicator Lamps
Page 41
39
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Indicator Lamps
Lamp Indicates Condition
Vehicle Speed
When standard mode is selected, speed displays in miles per hour.
When metric mode is selected, speed displays in kilometers per hour.
Over Temperature
This lamp flashes to indicate an overheated engine. If the indicator stops flashing but remains illuminated, the overheating condition remains, and the system will automatically reduce engine powe r.
EPS Warning (if equipped)
This indicator illuminates when the key is turned to the ON position and goes off when the engine is started. If the light remains on after starting the engine, the EPS system is inoperative. See your authorized POLARIS dealer for service.
Neutral This lamp illuminates when the transmission is in
neutral and the ignition key is in the ON position.
High Beam This lamp illuminates when the headlamp switch is
set to high beam.
Check Engine This indicator appears if an EFI-related fault occurs.
Do not operate the ATV if this warning appears. Serious engine damage could result. See your dealer.
Page 42
40
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The rider information center is located in the instrument cluster. All segments will light up for one second at start-up. If the instrument cluster fails to illuminate, a battery over-voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer. If this occurs, take the ATV to your POLARIS dealer for proper diagnosis.
The information center is set to display standard units of measurement and a 12-hour clock at the factory. To change to metric and/or a 24-hour clock, see page 43.
Trip 1
km
mi
RPM
EF
88
:
88
1
2
3
5
67
4
Page 43
41
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
1. Gear Display - This area displays gear shifter position: H = High Gear L = Low Gear N = Neutral R = Reverse Gear P = Park
-- = Gear Signal Error (or shifter between gears)
2. Fuel Gauge Display - The segments of the fuel gauge show the
level of fuel in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the
fuel sensor circuit. See your dealer.
3. Information Display - This area displays odometer, trip meter,
engine hour meter, engine speed and programmable service hour interval.
4. Active Descent Control Display (if equipped) - This icon displays
when ADC is active. See page 37.
5. Clock Display - The clock displays time in a 12-hour or 24-hour
format. If the engine is turned off, press the MODE button. The time will display for 5-10 seconds. See page 43 for resetting instructions.
6. Service Reminder Display - A flashing wrench symbol alerts the
operator that the preset service interval has been reached. The vehicle should be brought to your dealer for scheduled maintenance. See page 43 for resetting instructions.
7. 4X4 Display - This icon displays when the 4X4 system is engaged
(switch is on either ADC 4X4 (if equipped) or 4X4).
Page 44
42
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
The reverse override button acts as the MODE button when pressed and released quickly. The transmission cannot be in reverse when using the override button as a MODE button. This feature does not contain a vehicle speed lockout function and can be used at any operating speed.
Display Units (Standard/Metric)
The display can be changed to display either standard or metric units of measurement.
Tip: To exit the set-up mode at any time, wait 10 seconds. The display
automatically exits and returns to the odometer display.
1. Turn the key to the OFF position.
2. Place the transmission in neutral.
3. Press and hold the MODE button while turning the key to the ON position.
4. When the display flashes the distance setting, tap the MODE button to advance to the desired setting.
5. Press and hold the MODE button to save the setting and advance to the next display option.
6. Repeat the procedure to change remaining display settings.
Standard Display Metric Display
Distance Miles Kilometers Time 12-Hour Clock 24-Hour Clock
Page 45
43
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Clock Mode
Tip: The clock must be reset any time the battery has been disconnected or
discharged.
1. Turn the key to the ON position. Use the MODE button to toggle to the odometer display.
2. Press and hold the MODE button until the hour segment flashes.
Release the button.
3. With the segment flashing, tap the MODE button to advance to the
desired setting.
4. Press and hold the MODE button until the next segment flashes.
Release the button.
5. Repeat steps 3-4 twice to set the 10-minute and 1-minute segments.
After completing the 1-minute segment, step 4 will save the new settings and exit the clock mode.
6. Turn the key to the OFF position.
Odometer Mode
The odometer records and displays the distance traveled by the ATV.
Trip Meter Mode
The trip meter records the distance traveled by the ATV if reset before each trip. T o reset, select the trip meter mode. Press and hold the MODE button until the meter resets to zero. In the Rider Information Center , the trip meter display contains a decimal point, but the odometer displays without a decimal point.
Hour Meter Mode
This mode logs the total hours the engine has been in operation.
Page 46
44
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Programmable Service Interval
When the hours of engine operation equal the programmed service interval setting, the wrench icon will flash for 5 seconds each time the engine is started. When this feature is enabled, it provides a convenient reminder to perform routine maintenance. The service interval is programmed at 50 hours at the factory. Use the following procedure to change the service interval.
1. Press the MODE button until remaining service hours display.
2. Press and hold the MODE button.
3. When the service hours flash, press and release the MODE button to advance the hours to the desired setting (including OFF). Press and hold the MODE button to set the new service hour interval.
Diagnostic Display Mode
The EFI diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on. Leave the key on if you want to view the active code (failure code).
The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active. This allows the determination of persistent as well as intermittent faults.
Inactive codes are stored in the history of the unit.
Page 47
45
FEATURES AND CONTROLS
Instrument Cluster
Digital/Analog Gauge
Rider Information Center
Engine Error Codes
The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle. Error codes are not stored in the gauge when the key is turned off. The code and message is lost, but will reappear if the fault reoccurs after restarting the engine.
If the CHECK ENGINE light illuminates, retrieve the error codes from the display . Please see your Polaris dealer for all major repairs.
1. If the error codes are not displayed, use the MODE button to toggle until “Ck ENG” displays on the main line of the display.
2. Press and hold the MODE button to enter the diagnostics code
menu.
3. Record the numbers displayed in the gear position (if any), clock
and odometer displays.
4. Press the MODE button to advance to the next error code.
5. Press and hold the MODE button to exit the diagnostics code menu.
6. See pages 46-48 for code definitions and failure descriptions. Please
see your Polaris dealer for all major repairs.
Error Code
Number (0-9)
Suspect Parameter
Number (SPN)
Failure Mode Indicator (FMI)
Page 48
46
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground
: The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load
: The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery
: The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
Diagnostic Codes
Component Condition SPN FMI
Accelerator Position 2
Data Erratic, Intermittent Or Incorrect 29 2 Voltage Above Normal, Or Shorted To High Source 29 3 Voltage Below Normal, Or Shorted To Low Source 29 4
Throttle Position Sensor 1
Data Valid But Above Normal Operational Range - Most Severe Level
51 0
Data Valid But Below Normal Operational Range - Most Severe Level
51 1
Data Erratic, Intermittent Or Incorrect 51 2 Voltage Above Normal, Or Shorted To High Source 51 3 Voltage Below Normal, Or Shorted To Low Source 51 4 Abnormal Rate Of Change 51 10 Out Of Calibration 51 13
Vehicle Speed Sensor
Data Valid But Above Normal Operational Range - Most Severe Level
84 0
Data Valid But Below Normal Operational Range - Most Severe Level
84 1
Data Erratic, Intermittent Or Incorrect 84 2 Voltage Above Normal, Or Shorted To High Source 84 3 Voltage Below Normal, Or Shorted To Low Source 84 4 Abnormal Frequency Or Pulse Width Or Period 84 8 Abnormal Update Rate 84 9 Abnormal Rate Of Change 84 10 Bad Intelligent Device Or Component 84 12 Received Network Data In Error 84 19
Accelerator Position 1
Data Erratic, Intermittent Or Incorrect 91 2 Voltage Above Normal, Or Shorted To High Source 91 3 Voltage Below Normal, Or Shorted To Low Source 91 4
Manifold Absolute Pressure Sensor
Data Erratic, Intermittent Or Incorrect 102 2 Voltage Above Normal, Or Shorted To High Source 102 3 Voltage Below Normal, Or Shorted To Low Source 102 4 Mechanical System Not Responding Or Out Of Adjustment 102 7 Abnormal Rate Of Change 102 10
Page 49
47
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
Intake Air Temperature Sensor
Data Erratic, Intermittent Or Incorrect 105 2 Voltage Above Normal, Or Shorted To High Source 105 3 Voltage Below Normal, Or Shorted To Low Source 105 4 Abnormal Rate Of Change 105 10 Data Valid But Above Normal Operating Range - Least
Severe Level
105 15
Engine T emperatu re Sensor
Data Valid But Above Normal Operational Range - Most Severe Level
110 0
Data Erratic, Intermittent Or Incorrect 110 2 Voltage Above Normal, Or Shorted To High Source 110 3 Voltage Below Normal, Or Shorted To Low Source 110 4 Abnormal Rate Of Change 110 10 Data Valid But Above Normal Operating Range - Least
Severe Level
110 15
Data V alid But A bove Normal Operating Range - Mod erately Severe Level
110 16
Data Valid But Below Normal Operating Range - Least Severe Level
110 17
System Power Data Valid But Above Normal Operational Range - Most
Severe Level
168 0
Data Valid But Below Normal Operational Range - Most Severe Level
168 1
Voltage Above Normal, Or Shorted To High Source 168 3 Voltage Below Normal, Or Shorted To Low Source 168 4 Data V alid But A bove Normal Operating Range - Mod erately
Severe Level
168 16
Data V alid But Be low Normal Operating Range - Modera tely Severe Level
168 18
Engine Speed Data Valid But Above Normal Operational Range - Most
Severe Level
190 0
Data Valid But Below Normal Operational Range - Most Severe Level
190 1
Data Erratic, Intermittent Or Incorrect 190 2 Mechanical System Not Responding Or Out Of Adjustment 190 7 Received Network Data In Error 190 19 Condition Exists 190 31
Gear Sensor Signal Data Erratic, Intermittent Or Incorrect 523 2
Voltage Above Normal, Or Shorted To High Source 523 3 Voltage Below Normal, Or Shorted To Low Source 523 4 Abnormal Update Rate 523 9
ECU Memory Bad Intelligent Device Or Component 628 12
Out Of Calibration 628 13 Calibration Out Of Calibration 630 13 Crankshaft Position
Sensor
Data Erratic, Intermittent Or Incorrect 636 2
Abnormal Frequency Or Pulse Width Or Period 636 8 Injector 1 (Front)
(MAG) (SDI Port Injector)
Voltage Above Normal, Or Shorted To High Source 651 3
Voltage Below Normal, Or Shorted To Low Source 651 4
Current Below Normal Or Open Circuit 651 5
Page 50
48
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
Fan Relay Driver Circuit
Voltage Above Normal, Or Shorted To High Source 1071 3 Voltage Below Normal, Or Shorted To Low Source 1071 4 Current Below Normal Or Open Circuit 1071 5
Ignition Coil Primary Driver 1 (Front) (MAG)
Voltage Above Normal, Or Shorted To High Source 1268 3 Voltage Below Normal, Or Shorted To Low Source 1268 4 Current Below Normal Or Open Circuit 1268 5
Fuel Pump Driver Circuit
Voltage Above Normal, Or Shorted To High Source 1347 3 Voltage Below Normal, Or Shorted To Low Source 1347 4 Current Below Normal Or Open Circuit 1347 5
Oxygen Sensor 1 Data Erratic, Intermittent Or Incorrect 3056 2
Voltage Above Normal, Or Shorted To High Source 3056 3 Voltage Below Normal, Or Shorted To Low Source 3056 4 Bad Intelligent Device Or Component 3056 12
ECU Output Supply Voltage 1
Data Valid But Above Normal Operational Range - Most Severe Level
3597 0
Data Valid But Below Normal Operational Range - Most Severe Level
3597 1
Voltage Above Normal, Or Shorted To High Source 3597 3 Voltage Below Normal, Or Shorted To Low Source 3597 4 Data V alid But A bove Normal Operating Range - Moderately
Severe Level
3597 16
Data V alid But Be low Normal Operating Range - Modera tely Severe Level
3597 18
ECU Output Supply Voltage 2
Data Valid But Above Normal Operational Range - Most Severe Level
3598 0
Data Valid But Below Normal Operational Range - Most Severe Level
3598 1
Voltage Above Normal, Or Shorted To High Source 3598 3 Voltage Below Normal, Or Shorted To Low Source 3598 4 Data V alid But A bove Normal Operating Range - Moderately
Severe Level
3598 16
Data V alid But Be low Normal Operating Range - Modera tely Severe Level
3598 18
ECU Output Supply Voltage 3
Data Valid But Above Normal Operational Range - Most Severe Level
3599 0
Data Valid But Below Normal Operational Range - Most Severe Level
3599 1
Voltage Above Normal, Or Shorted To High Source 3599 3 Voltage Below Normal, Or Shorted To Low Source 3599 4 Data V alid But A bove Normal Operating Range - Moderately
Severe Level
3599 16
Data V alid But Be low Normal Operating Range - Modera tely Severe Level
3599 18
ETC Accelerator Position Sensor Outputs 1 & 2 Correlation
Data Erratic, Intermittent Or Incorrect 65613 2
Page 51
49
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
Throttle Position Sensor 2 Data Valid But Above Normal Operational Range -
Most Severe Level
520198 0
Data Valid But Below Normal Operational Range ­Most Severe Level
520198 1
Data Erratic, Intermittent Or Incorrect 520198 2 Voltage Above Normal, Or Shorted To High Source 520198 3 Vol tage Below Normal, Or Shorted To Low Source 520198 4 Abnormal Rate Of Change 520198 10 Out Of Calibration 520198 13
Active Descent Control System
Voltage Above Normal, Or Shorted To High Source 520203 3 Vol tage Below Normal, Or Shorted To Low Source 520203 4 Current Below Normal Or Open Circuit 520203 5
Fuel Correction Front Data Valid But Above Normal Operating Range -
Least Severe Level
520204 15
Data Valid But Below Normal Operating Range ­Least Severe Level
520204 17
All Wheel Drive Control Circuit
Voltage Above Normal, Or Shorted To High Source 520207 3 Vol tage Below Normal, Or Shorted To Low Source 520207 4 Current Below Normal Or Open Circuit 520207 5
Oxygen Sensor Heater 1 Data Erratic, Intermittent Or Incorrect 520209 2
Voltage Above Normal, Or Shorted To High Source 520209 3 Vol tage Below Normal, Or Shorted To Low Source 520209 4 Current Below Normal Or Open Circuit 520209 5
Accelerator Position/Brake Position Interaction
Condition Exists 520275 31
Throttle Position Sensor (1 or 2 Indeterminable)
Data Erratic, Intermittent Or Incorrect 520276 2 Bad Intelligent Device Or Component 520276 12
Throttle Body Control ­Power Stage
Data Erratic, Intermittent Or Incorrect 520277 2 Voltage Above Normal, Or Shorted To High Source 520277 3 Vol tage Below Normal, Or Shorted To Low Source 520277 4 Abnormal Frequency Or Pulse Width Or Period 520277 8 Condition Exists 520277 31
Throttle Body Control ­Return Spring Check Failed
Condition Exists 520278 31
Throttle Body Control ­Adaption Aborted
Condition Exists 520279 31
Throttle Body Control ­Limp Home Position Check Failed
Condition Exists 520280 31
Throttle Body Control ­Mechanical Stop Adaptation Failure
Condition Exists 520281 31
Throttle Body Control ­Repeated Adaptation Failed
Condition Exists 520282 31
Throttle Body Control Data Erratic, Intermittent Or Incorrect 520283 2
Voltage Above Normal, Or Shorted To High Source 520283 3 Vol tage Below Normal, Or Shorted To Low Source 520283 4
Page 52
50
FEATURES AND CONTROLS
Instrument Cluster
Diagnostic Display Code Definitions
Diagnostic Codes
Component Condition SPN FMI
Throttle Body Control - Position Deviation Fault
Condition Exists 520284 31
ECU Monitoring Error Condition Exists 520286 31 ECU Monitoring Error (Level 3) Condition Exists 520287 31 ECU Monitoring of Injection Cut Off
(Level 1)
Condition Exists 520288 31
ECU Monitoring of Injection Cut Off (Level 2)
Condition Exists 520289 31
Throttle Body Control - Requested Throttle Angle Not Plausible
Condition Exists 520305 31
ECU ADC Fault - No Load Condition Exists 520306 31 ECU ADC Fault - Voltage Condition Exists 520307 31 Accelerator Sensor Sync Fault - Sensor
Diff Exceeds Limit
Condition Exists 520308 31
ECU Fault - ICO Condition Exists 520309 31 ECU Fault - Hardware Disruption Condition Exists 520311 31 Idle Fuel Correction Bank 1 Data Valid But Above Normal
Operating Range - Least Severe
520342 15
Data Valid But Below Normal Operating Range - Least Severe
520342 17
Adaptive Fuel Correction Bank 1 Data Valid But Above Normal
Operating Range - Least Severe
520344 15
Data Valid But Below Normal Operating Range - Least Severe
520344 17
EPS Models Only
Steering Over Current Shut Down Current Above Normal Or Grounded
Circuit
520221 6
Steering Excessive Current Error Current Above Normal Or Grounded
Circuit
520222 6
Steering Torque Partial Failure Condition Exists 520223 31 Steering Torque Full Failure Condition Exists 520224 31 EPAS Inverter Temperature Data Valid But Above Normal
Operational Range - Most Severe
520225 0
Data Valid But Above Normal Operating Range - Severe
520225 16
EPAS Communications Receive Data Error
Data Erratic, Intermittent Or Incorrect 520226 2 Condition Exists 520226 31
Position Encoder Error Root Cause Not Known 520228 11
Bad Intelligent Device Or Component 520228 12 Condition Exists 520228 31
EPAS Software Error Bad Intelligent Device Or Component 520229 12
Condition Exists 520229 31 EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Volt age Error Vol tage Above Normal, Or Shorted To
High Source
524086 3
Vol tage Below Nor mal, Or Shorted To
Low Source
524086 4
Page 53
51
OPERATION
Failure to operate the ATV properly can result in a collision, loss of control, accident or rollover, which may result in serious injury or death. Read and understand all safety warnings outlined in the safety section of this owner ’s manual.
Break-In Period
The break-in period for your new POLARIS ATV is the first 20 hours of operation. 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.
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 oil level on the dipstick. See page 92. Add oil if
necessary to maintain the level between the safe and add marks.
3. Drive slowly at first. Select an open area that allows room to
familiarize yourself with vehicle operation and handling.
4. Vary the throttle positions. Do not operate at sustained idle.
5. Perform regular checks on fluid levels, controls and areas outlined
on the daily pre-ride inspection checklist. See page 54.
6. Pull only light loads.
7. Change both the oil and the filter at 25 hours.
8. Check fluid levels of transmission and all gearcases after the first 25
hours of operation and every 100 hours thereafter.
WARNING
Page 54
52
OPERATION
Break-In Period
PVT Break-in (Clutches/Belt)
A proper break-in of the clutches and drive belt will ensure a longer life and better performance. Break in the clutches and belt by operating at slower speeds during the break-in period as recommended. Pull only light loads. Avoid aggressive acceleration and high speed operation during the break-in period.
If a belt fails, always clean away all debris when replacing the belt.
Safe Operation Practices
1. Complete the recommended safety training before operating this vehicle. See page 7.
2. Do not allow anyone under 16 years of age to operate this vehicle.
Do not allow anyone with cognitive or physical disabilities to operate this vehicle.
3. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Before operating, learn how to use the auxiliary brake for
emergency situations (if service brakes become inoperable).
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights frequently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills, your passenger’s
skills and operating conditions. Never operate at excessive speeds. Never attempt wheelies, jumps, or other stunts. Never remove your hands from the handlebars while operating, and always keep both feet on the footrests.
8. Never consume alcohol or drugs before or while operating an ATV.
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OPERATION
Safe Operation Practices
9. Always use the size and type of tires specified for your vehicle. Always maintain proper tire pressure.
10. Never operate a damaged ATV. After any rollover or accident, have a qualified service dealer inspect the entire machine for possible damage.
11. Never operate the ATV on a frozen body of water unless you have independently verified that the ice is suf ficiently thick to support the weight and moving force of the ATV, you and your cargo, together with any other vehicles in your party.
12. Do not touch hot exhaust system components. Always keep combustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to prevent unauthorized use.
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.
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54
OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition before operating increases the risk of an accident. Always inspect the ATV before each use to make sure it's in safe operating condition.
Item Remarks Page
Brake system/lever travel Ensure proper operation 29
100 Brake fluid Ensure proper level 30 Auxiliary brake Ensure proper operation 32 Front suspension Inspect, lubricate if necessary 90 Rear suspension Inspect, lubricate if necessary 90 Steering Ensure free operation ­Tires Inspect condition and pressure 105 Wheels/fasteners Inspect, ensure fastener tightness 105
106 Frame nuts, bolts, fasteners Inspect, ensu re tightn ess ­Fuel and oil Ensure proper levels 33
92
Coolant level (if applicable) Ensure proper level 98
99 Coolant hoses (if applicable) Inspect for leaks ­Throttle Ensure proper operation 28
130 Indicator lights/switches Ensure operation 26 Engine stop switch Ensure proper operation 27 Air filter, pre-filter Inspect, clean 107 Air box sediment tube Drain deposits whenever visible ­Headlamp Check operation, apply POLARIS
dielectric grease when lamp is replaced
27
110 Brake light/taillight Check operation, apply POLARIS
dielectric grease when lamp is replaced
115
Riding gear Wear approved helmet, goggles, and
protective clothing
8
Winch (if equipped) Inspect cable and switch 73-84
Page 57
55
OPERATION
Starting the Engine
1. Position the vehicle on a level surface outdoors or in a well­ventilated 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
damage. Allow the engine to warm up for several minutes before operating the vehicle.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil level could indicate the accumulation of 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.
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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.
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57
OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on this 2-up AT V. Make sure any passenger is tall enough to comfort­ably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear, includ-
ing an approved helmet with a rigid chin guard. See page 8.
4. Perform the pre-ride
inspection. See page 54.
5. Lock the parking brake.
6. Mount the vehicle from
the left side. After the operator is seated, the passenger should mount the vehicle from the left side. Always make sure the brake is engaged to ensure the vehicle remains motionless whenever a passenger mounts or dismounts.
7. Allow a passenger to ride only in the approved passenger seat.
8. Do not carry more than one passenger.
9. Slow down. Control may be more difficult with a passenger on
board. Allow more time and distance for braking.
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OPERATION
Driving with a Passenger
10. Ride to the ability of your passenger, instead of to your own ability. Avoid unexpected or aggressive maneuvers that could cause a passenger to fall from the vehicle.
11. Do not cross a hillside with a passenger on board. See page 62.
12. A passenger should always be seated in the passenger seat with both feet on the footrests and both hands on the passenger grab handles at all times. The passenger should never hold on to the operator. Never secure a passenger to the vehicle or to the operator with a belt, rope or similar device.
13. Make sure the passenger understands the importance of “active riding.” When hill-climbing or performing maneuvers, a passenger should shift body weight in the same manner in which the driver shifts body weight. For example, the passenger should lean to the inside of a turn along with the operator and should always lean uphill when climbing and descending hills.
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59
OPERATION
Turning the Vehicle
Your ATV 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.
1. Slow down.
2. Never turn quickly when carrying a passenger or cargo.
3. Steer in the direction of the turn.
4. Keep both feet on the footrests.
5. Lean your upper body to the inside of the turn while supporting your weight on the outer footrest. This technique alters the balance of traction between the rear wheels, allowing the turn to be made smoothly . The same leaning technique should be used for turning in reverse.
6. Practice making turns at slow speeds before attempting to turn at faster speeds.
WARNING! Turning improperly can result in vehicle rollover. Never turn abruptly or at sharp angles. Never turn at high speeds.
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60
OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel, or during freezing weather, follow these precautions:
1. 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.
Turn in Direction
of Skid
Sideways
Skid
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61
OPERATION
Driving Uphill
Braking and handling are greatly affected when operating in hilly terrain. Improper procedure could cause loss of control or rollover. 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 37.
2. Drive straight uphill.
3. Avoid steep hills (15° 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. A passenger should also shift body weight
uphill.
8. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
9. Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the hill.
10. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
15° Maximum
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62
OPERATION
Driving on a Sidehill (Sidehilling)
Driving on a sidehill is not recommended. Improper procedure could cause loss of control or rollover. Avoid crossing the side of any hill unless absolutely necessary.
If crossing a sidehill is unavoidable, follow these precautions:
1. Slow down.
2. Avoid crossing the side of a steep hill.
3. Do not cross a hillside with a passenger on board. Ask the passenger to dismount and walk across the hillside before remounting the vehicle.
4. Lean into the hill, transferring your upper body weight toward the hill while keeping 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!
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63
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 37.
2. Avoid steep hills (15° maximum).
3. Always check the terrain carefully before descending a hill.
4. Always descend a hill with the transmission in forward gear . Do not
descend a hill with the transmission in neutral.
5. Slow down. Never travel down a hill at high speed.
6. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.
7. Shift body weight uphill. A passenger should also shift body weight
uphill.
8. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss of control.
15° Maximum
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64
OPERATION
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.
8 ft. (2.4 m)
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65
OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Always move the 4X4 switch to ADC 4X4 (if equipped) before
ascending or descending a hill. See page 37.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then
the operator may dismount. Dismount on the uphill side of the vehi­cle, or on the left if the vehicle is pointing straight uphill. A passen-
ger should not remount until the vehicle returns to firm, level ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's pointing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill. A passenger should not remount until the vehicle returns to firm, level ground.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
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66
OPERATION
Driving Through Water
Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests. Follow these procedures when operating through water:
1. Determine water depths and current before entering water.
2. Choose a crossing where both banks have gradual inclines.
3. Avoid operating through deep or fast-flowing water.
Maximum Depth
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OPERATION
Driving Through Water
NOTICE: Major engine damage can result if the vehicle is not thoroughly
inspected after operation in water. Perform the services outlined in the maintenance chart. See page 86. 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 118, then see your dealer for service at the first opportunity.
4. After leaving water, test the brakes. Apply them lightly several
times while driving slowly. The friction will help dry out the pads.
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.
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68
OPERATION
Driving in Reverse
Follow these precautions when operating in reverse:
1. Always check for obstacles or people behind the vehicle. Be aware that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override 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.
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OPERATION
Hauling Cargo
Overloading the vehicle or carrying or towing cargo improperly can alter vehicle handling and may cause loss of control or brake instability, which can result in serious injury or death. Always follow these precautions when hauling cargo:
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When determining the weight you are adding to the vehicle, include the weight of the operator, passenger, accessories, loads in the rack or box and the load on the trailer tongue. The combined weight of these items must not exceed the maximum weight capacity.
CARGO WEIGHT DISTRIBUTION should be 1/3 on the front rack and 2/3 on the rear rack. When operating over rough or hilly terrain, reduce speed and cargo to maintain stable driving conditions. Carrying loads on only one rack increases the possibility of vehicle rollover.
CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE. Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads can create unstable operating conditions, which could result in loss of control of the vehicle.
OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS. When handling off-centered loads that cannot be centered, securely fasten the load and operate with extra caution. Always attach the tow load to the hitch point designated for your vehicle.
HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS. Use extreme caution when applying brakes with a loaded vehicle. Avoid terrain or situations that may require backing downhill.
USE EXTREME CAUTION when operating with loads that extend over the rack sides. Stability and maneuverability may be adversely affected, causing vehicle rollover.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the front rack.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. NEVER exceed 50 MPH (80 km/h) when rear cargo loads are above 75 lbs. (34
kg) and/or front cargo loads are above 37 lbs. (17 kg). NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
V ehicle should never exceed 10 MPH (16 km/h) while towing a load on a level surface. Vehicle speed should never exceed 5 MP H (8 km/h) when towing loads in rough terrain, while cornering, or while ascending or descending a hill.
WARNING
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OPERATION
Hauling Cargo
1. Never exceed the weight capacities specified for your ATV on warning labels and in the specifications section of this manual.
2. Cargo weight should be
evenly distributed (1/3 on the front rack and 2/3 on the rear rack) and mounted as low as possible.
3. NEVER exceed 50 MPH
(80 km/h) when rear cargo loads are above 75 lbs. (34 kg) and/or front cargo loads are above 37 lbs. (17 kg).
4. NEVER exceed 50 MPH (80 km/h) while carrying a passenger.
5. When operating over rough or hilly terrain, reduce speed and cargo
weight to maintain stable driving conditions.
6. Do not obstruct the headlight beam with cargo.
7. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
8. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
1/3
2/3
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71
OPERATION
Hauling Cargo
Towing Loads
Always attach a towed load to the hitch point. Remove the hitch from the ATV when not towing a trailer. If towing a load, reduce rear rack cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity.
• The total load (operator, passenger, accessories, cargo and weight on hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or exceeding
the maximum tongue weight capacity can result in serious damage to the vehicle and will void your ATV warranty. Never install a hitch longer than 4" (10 cm). Never install automotive accessories on your POLARIS ATV. Always install POLARIS-approved (or equivalent) accessories designed for ATV use.
Maximum
4" (10 cm)
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72
OPERATION
Driving Over Obstacles
Follow these precautions when operating over
obstacles:
1. Always check for obstacles before operating in a new area.
2. Look ahead and learn to
read the terrain. Be constantly alert for hazards such as logs, rocks and low hanging branches.
3. Travel slowly and use extra caution when operating on unfamiliar
terrain. Not all obstacles are immediately visible.
4. Never attempt to operate over large obstacles, such as rocks or
fallen trees.
5. Always have a passenger dismount before operating over an
obstacle that could cause a fall from the vehicle or vehicle tipover.
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.
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73
WINCH GUIDE
These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Your winch may have a cable made of either wire rope or specially designed synthetic rope. The term “winch cable” will be used for either unless noted otherwise.
Winch Safety Precautions
1. Read all sections of this manual.
2. Never use alcohol or drugs before or while operating the winch.
3. Never allow children under 16 years of age to operate the winch.
4. Always wear eye protection and heavy gloves when operating the winch.
5. Always keep body, hair, clothi ng and jewelry clear of the winch cable, fairlead and hook when operating winch.
6. Never attempt to “jerk” a load attached to the winch with a moving vehicle. See the Shock Loading section on page 82.
7. Always keep the area around the vehicle, winch, winch cable and load clear of people (especially children) and distractions while operating the winch.
8. Always turn the vehicle ignition power OFF when it and the winch are not being used.
9. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
10. Always apply your vehicle’s park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.
WARNING
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WINCH GUIDE
Winch Safety Precautions
11. Always align the vehicle and winch with the load directly in front of the vehicle as much as possible. Avoid winching with the winch cable at an angle to the winching vehicle’s centerline whenever possible.
12. If winching at an angle is unavoidable, follow these precautions:
A. Look at the winch drum occasionally . Never let the winch cable “stack”
or accumulate at one end of the winch drum. Too much winch cable at one end of the winch drum can damage the winch and the winch cable.
B. If stacking occurs, stop winching. Follow step 15 on page 80 to feed
and rewind the cable evenly before continuing the winch operation.
13. Never winch up or down at sharp angles. This can destabilize the winching vehicle and possibly cause it to move without warning.
14. Never attempt to winch loads that weigh more than the winch’s rated capacity.
15. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
16. Never touch, push, pull or straddle the winch cable while winching a load.
17. Never let the winch cable run through your hands, even if wearing heavy gloves.
18. Never release the clutch on the winch when the winch cable is under load.
19. Never use the winch for lifting or transporting people.
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WINCH GUIDE
Winch Safety Precautions
20. Never use the winch to hoist or suspend a vertical load.
21. Never immerse or submerse your winch in water. Take your winch to your dealer for service if this occurs.
22. Always inspect your winch and winch cable before each use.
23. Never winch the hook fully into the winch. This can cause damage to winch components.
24. Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons.
25. Never grease or oil the winch cable. This will cause the winch cable to collect debris that will shorten the life of the cable.
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WINCH GUIDE
Winch Operation
Read the Winch Safety Precautions in the preceding pages before using your winch.
Tip: Consider practicing the operation and use of your winch before you actually
need to use it in the field.
Improper winch use can result in SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
Each winching situation is unique.
• Take your time to think through the winching you are about to do.
• Proceed slowly and deliberately.
• Never hurry or rush during winching.
• Always pay attention to your surroundings.
• You may need to change your winching strategy if it is not working.
• Always remember that your winch is very powerful.
• There are simply some situations that you and your winch will not be able to deal with. Do not be afraid to ask others to help when this happens.
1. Always inspect the vehicle, winch, winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use. Pay particular attention to the first 3 feet (1 meter)
of winch cable if the winch is being used (or has been used) for lift­ing an accessory plow assembly. Promptly replace any worn or
damaged cable.
2. Never operate a winch or a vehicle in need of repair or service.
3. Always apply your vehicle’s
park brake and/or park mechanism to hold the vehicle in place during winching. Use wheel chocks if needed.
WARNING
Hook Strap
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WINCH GUIDE
Winch Operation
4. Always use the hook strap when handling the hook.
WARNING! Never put your fingers into the hook. This could lead to SEVERE INJURY.
A. Attach the hook itself onto the
load or use a tow strap or chain to secure the load to the winch cable.
Tip: A “tow strap” is NOT intended to stretch. A “recovery strap” is designed to
stretch.
WARNING! Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks. This can result in SEVERE INJURY or DEATH. See the Shock Loading section on page 82.
B. Never hook the winch cable back onto itself. This will damage the
winch cable and may result in winch cable failure.
WARNING! Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure. For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
C. If possible, keep the winch cable aligned with the centerline of the
winching vehicle. This will help the spooling of the winch cable and reduce the load on the fairlead.
D. If freeing a stuck vehicle by attaching to a tree, use an item such as a
tow strap to avoid damaging the tree during winch operation. Sharp cables and chains can damage and even kill trees. Please remember to TreadLightly® (treadlightly.org).
E. Before operating the winch, be sure
that the safety latch on the winch cable hook is fully seated when the load is attached.
F. Never operate your winch with a
damaged hook or latch. Always replace damaged parts before using the winch.
NO YES
NO
YES
Page 80
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WINCH GUIDE
Winch Operation
5. Never remove the hook strap from the hook.
6. Release the winch clutch and pull out the winch cable.
7. Pulling out as much cable as possible maximizes the winch’ s pulling capacity. Always be sure that at least five (5) full turns of winch cable are wrapped around the winch drum at all times. The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load.
8. Read and adhere to the following information for winch damping to ensure safe winch use.
A. In order to absorb energy that could be released by a winch cable
failure, always place a “damper” on the winch cable. A damper can be a heavy jacket, tarp, or other soft, dense object. A damper can absorb much of the energy released if a winch cable breaks when winching. Even a tree limb can help as a damper if no other items are available to you.
B. Lay the damper on top of the mid-point of the winch cable length that is
spooled out.
C. On a long pull, it may be necessary to stop winching so that the
damper can be repositioned to the new mid-point of the winch cable. Always release the tension on the winch cable before repositioning the damper.
D. Avoid being directly in line with the winch cable whenever possible.
Also, never permit others to stand near or in line with the winch cable during winch operation.
9. Never hook the winch cable back onto itself. This will damage the winch cable and may result in winch cable failure.
10. Never use straps, chains or other rigging items that are damaged or worn.
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WINCH GUIDE
Winch Operation
11. The ONLY time a winch-equipped vehicle should be moving when using the winch is when that vehicle itself is stuck. The winch­equipped vehicle should NEVER be in motion to “shock” load the winch cable in an attempt to move a second stuck vehicle. See the Shock Loading section on page 82. For your safety, always follow these guidelines when winching a vehicle free:
A. Release the winch clutch and spool out the necessary length of winch
cable.
B. Align the winch cable as close as possible to the winching vehicle’s
centerline.
C. Attach the winch cable hook to the anchor point or the stuck vehicle’s
frame following instructions in this manual. D. Re-engage the clutch on the winch. E. Slowly winch in the slack in the winch cable. F. Select the proper vehicle gear to propel the stuck vehicle in the
direction of winching. G. Shift to the lowest gear available on the stuck vehicle. H. Slowly and carefully apply vehicle throttle an d winch together to free
the vehicle. I. Stop winching as soon as the stuck vehicle is able to propel itself
without the help of the winch. J. Detach the winch cable hook. K. Rewind the winch cable evenly back onto the winch drum following the
instructions in this manual.
12. Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component, brush guard, bumper or cargo rack. Vehicle damage may result. Instead, attach the winch to a strong portion of the vehicle frame or hitch.
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WINCH GUIDE
Winch Operation
13. Extensive winching will run down the battery on the winching vehicle. Let the winching vehicle’s engine run while operating the winch to prevent the battery from running low if winching for long periods.
14. The winch motor may become hot during winch use. If you winch for more than 45 seconds, or if the winch stalls during operation, stop winching and permit the winch to cool down for 10 minutes before using it again.
15. After winching is complete, especially if winching at an angle, it may be necessary to re-distribute the winch cable across the winch drum. You will need an assistant to perform this task.
A. Release the clutch on the winch. B. Feed out the winch cable that is unevenly bunched up in one area. C. Re-engage the winch clutch. D. Have an assistant pull the winch cable tightly with about 100 lbs. (45
kg) of tension using the hook strap.
E. Slowly winch the cable in while your assistant moves the end of the
winch cable back and forth horizontally to evenly distribute the winch cable on the drum.
F. Doing this reduces the chances of the winch cable “wedging” itself
between lower layers of winch cable.
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WINCH GUIDE
Winch Cable Care
For your safety, always replace POLARIS winch parts (including the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
WARNING! Use of worn or damage d cable could lead to sudden failure and SEVERE INJURY.
1. Always inspect your winch before each use. Inspect for worn or loose parts including mounting hardware. Never use the winch if any part needs repair or replacement.
2. Always inspect your winch cable before each use. Inspect for worn
or kinked winch cable.
A. A kinked winch cable made of
wire rope is shown at right. Even after being “straightened out,” this cable has already been permanently and severely damaged. Promptly discontinue use of a winch cable in this condition.
B. A kinked winch cable made of
wire rope that has been “straightened out” is shown at right. Even though it may look usable, the cable has been permanently and severely damaged. It can no longer transmit the load that it could prior to kinking. Promptly discontinue use of a winch cable in this condition.
C. A winch cable made of
synthetic rope should be inspected for signs of fraying. Replace the cable if fraying is observed (shown at right). Promptly discontinue use of a winch cable in this condition.
D. Also replace the winch cable if there are fused or melted fibers. Such
an area of the synthetic rope will be stiff and appear smooth or glazed. Promptly discontinue use of a winch cable in this condition.
A
B
C
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WINCH GUIDE
Shock Loading
WARNING! Your winch cable is very strong but it is NOT designed for dynamic,
or “shock” loading. Shock loading may tension a winch cable beyond its strength and cause the cable to break. The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders.
Winch cables are designed to NOT absorb energy. This is true of both wire-rope and synthetic-rope winch cables.
1. Never attempt to “jerk” a load with the winch. For example, never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object. This is a dangerous practice. It gener­ates high winch cable loads that may exceed the strength of the cable. Even a slowly moving vehicle can create large shock loads in a winch cable.
WARNING! SEVERE INJURY or DEATH can result from a broken winch cable.
2. Never quickly turn the winch ON and OFF repeatedly (“jogging”).
This puts extra load on the winch, winch cable, and generates excessive heat from the motor. This is a form of shock loading.
3. Never tow a vehicle or other object with your winch. Towing an
object with a winch produces shock loading of the cable even when towing at slow speeds. Towing from a winch also positions the towing force high on the vehicle. This can cause instability of the vehicle and possibly lead to an accident.
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WINCH GUIDE
Shock Loading
4. Never use recovery straps with your winch. Recovery straps are designed to stretch and can store energy. This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous. Similarly, never use elastic “bungie” cords for winching.
5. Never use the winch to tie down a vehicle to a trailer or other transportation vehicle. This type of use also causes shock loading that can cause damage to the winch, winch cable, or vehicles used.
Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle. Always remember that the winch and wi nch cable ar e NOT designed for shock loading.
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WINCH GUIDE
Winch Maintenance and Service Safety
WARNING! Improper or lack of winch maintenance and service could lead to
SEVERE INJURY or DEATH. Always follow all winch instructions and warnings in this manual.
1. Always inspect your winch before each use. Inspect for worn or kinked winch cable. Also inspect for worn or loose parts including mounting hardware.
2. Permit your winch motor to cool down prior to servicing your
winch.
3. Never work on your winch without first disconnecting the battery
connections to prevent accidental activation of the winch.
4. For your safety, always replace POLARIS winch parts (including
the cable) with genuine POLARIS replacement parts available at your authorized POLARIS dealer.
5. Some winch models use wire rope as the winch cable. Other
winches use a specially designed synthetic rope as the winch cable.
6. Never replace a synthetic-rope winch cable with a consumer-grade
polymer rope such as can be purchased in a hardware store. Although they may look similar, they are NOT alike. A polymer rope not designed for winch use will stretch and store excessive energy when winching.
WARNING! Failure of a stretched rope under winching conditions will release all of the stored energy. This will increase the chances of SEVERE INJURY or DEATH.
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EMISSION CONTROL SYSTEMS
Noise Emission Control System
Do not modify the engine, intake or exhaust components, as doing so may affect compliance with U.S.A. EPA noise control requirements (40 CFR 205) and local noise level requirements.
Operation on Public Lands in the U.S.A.
Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100-1c. Federal law requires that this spark arrester be installed and functional when the vehicle is operated on public lands.
Operation of off-road vehicles on public lands in the U.S.A. is regulated by 43 CFR 420. Vi olations are subject to monetary penalties. Federal regulations can be viewed online at www.gpoaccess.gov/ecfr/.
Crankcase Emission Control System
This engine is equipped with a closed crankcase system. Blow-by gases are forced back to the combustion chamber by the intake system. All exhaust gases exit through the exhaust system.
Exhaust Emission Control System
Exhaust emissions are controlled by engine design. An electronic fuel injection (EFI) system controls fuel delivery. The engine and EFI components are set at the factory for optimal performance and are not adjustable.
The emissions label is located on the right front frame of the vehicle.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002. This vehicle complies with the EMC requirements of European
directives 97/24/EC and 2004/108/EC. Non-ionizing Radiation: This vehicle emits some electromagnetic
energy. People with active or non-active implantable medical devices (such as heart monitoring or controlling devices) should review the limitations of their device and the applicable electromagnetic standards and directives that apply to this vehicle.
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MAINTENANCE
Periodic Maintenance Chart
Careful periodic maintenance will help keep your vehicle in safe, reli­able condition. 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
153.
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.
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MAINTENANCE
Periodic Maintenance Chart
Maintenance Chart Key
WARNING! Improperly performing the procedures marked with a “D” could
result in component failure and lead to serious injury or death. Have an authorized POLARIS dealer perform these services.
Perform all services at whichever maintenance interval is reached first.
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Symbol Description
Ź Perform these operations more often for vehicles subjected to severe use.
E Emission-related service (failure to conduct this maintenance will not void
the emissions warranty but may affect emissions)
D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Steering -
Pre-Ride
-
Make adjustments as need ed. See Pre-Ride Checklist on page 54.
Front suspension - ­Rear suspension - ­Tires - ­Brake fluid level - ­Brake lever travel - ­Brake system - ­Wheels/fasteners - ­Frame fasteners - ­Engine oil level - ­Winch (if equipped) - - See pages 73-84
Ź
E
Air filter, pre-filter - Daily - Inspect; clean often; replace
as needed
Ź Air box sediment
tube
- Daily - Drain deposits when visible
Coolant - Daily - Check level Power steering unit
(if equipped)
- Daily - Inspect daily; clean often
Headlight/taillight/ worklight
- Daily - Check operation; apply dielectric grease if replacing lamps
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MAINTENANCE
Periodic Maintenance Chart
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Ź
E
Air filter, main element
- Weekly - Inspect; replace as needed
Recoil housing - Weekly - Drain water as needed,
check often if operating in wet conditions
Ź
D
Brake pad wear 10 H Monthly 100 (160) Inspect periodically
Battery 20 H Monthly 200 (320) Check terminals; clean; test Fuel System 20 H Monthly - Inspect; cycle key to
pressurize fuel pump; check lines and fittings for leaks and abrasion
Ź
E
Engine breather valve (if equipped)
25 H Monthly 250 (400) Inspect; clean if needed
Ź Engine oil change 25 H 1 M 250 (400) Break-in oil and filter change Ź Demand drive fluid 25 H 1 M 250 (400) Break-in oil level check;
change fluid every 25 hours if ADC is subjected to extreme use. See page 97.
Ź Rear gearcase oil 25 H 1 M 250 (400) Break-in oil level check Ź Transmission oil 25 H 1 M 250 (400) Break-in oil level check Ź General lubrication 50 H 3 M 500 (800) Lubricate all fittings, pivots,
cables, etc.
DEThrottle Cable/
Release Switch
50 H 6 M 500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
Intake Duct
50 H 6 M 500 (800) Inspect duct for proper
sealing/air leaks
Drive belt 50 H 6 M 500 (800) Inspect; adjust; replace as
needed
Cooling system 50 H 6 M 1000 (1600) Inspect coolant strength
seasonally; pressure test system yearly
Ź Engine oil change 100 H 6 M 1000 (1600) Change the oil and filter Ź Oil lines and
fasteners
100 H 6 M 1000 (1600) Inspect for leaks and loose
fittings
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MAINTENANCE
Periodic Maintenance Chart
Ź Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service D Have an authorized POLARIS dealer perform these services.
Item Maintenance Interval
(whichever comes first)
Remarks
Hours Calendar Miles
(Km)
Ź Demand drive fluid
(normal use)
100 H 12 M 1000 (1600) Change fluid; change fluid
every 25 hours if ADC is subjected to extreme use. See page 97.
Ź Rear gearcase oil 100 H 12 M 1000 (1600) Change fluid Ź Transmission oil 100 H 12 M 1000 (1600) Change fluid
DEValve clearance 100 H 12 M 1000 (1600) Inspect; adjust
DEFuel system/filter 100 H 12 M 1000 (1600) Cycle key to pressurize fuel
pump; check for leaks at fill cap, fuel lines/rail and fuel pump; replace lines every two years
Ź Radiator (if
applicable)
100 H 12 M 1000 (1600) Inspect; clean external
surfaces
Ź Cooling hoses (if
applicable)
100 H 12 M 1000 (1600) Inspect for leaks
Ź Engine mounts 100 H 12 M 1000 (1600) Inspect
Exhaust muffler/ pipe
100 H 12 M 1000 (1600) Inspect
DESpark plug 100 H 12 M 1000 (1600) Inspect; replace as needed
Ź Wiring 100 H 12 M 1000 (1600) Inspect for wear, routing,
security; apply dielectric grease to connectors subjected to water, mud, etc.
D Clutches (drive
and driven)
100 H 12 M 1000 (1600) Inspect; clean; replace worn
parts
D Front wheel
bearings
100 H 12 M 1000 (1600) Inspect; replace as needed
D Brake fluid 200 H 24 M 2000 (3200) Change every two years
Spark arrester 300 H 36 M 3000 (4800) Clean out
Ź Coolant - 60 M - Replace coolant
Idle speed - Adjust as needed
D Toe adjustment - Inspect periodically; adjust
when parts are replaced
Headlight aim - Adjust as needed
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MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 86. 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 Capacity at
Fluid Change
Inspection Procedure
Engine Oil PS-4 5W-50
4-Cycle Oil
2 qt. (1.9 l) Maintain level in safe range
on dipstick. See page 92.
Brake Fluid DOT 4 Brake Fluid --- Maintain level between fill
lines. See page 30.
Transmission Oil AGL Gearcase
Lubricant & Transmission Fluid
32 oz. (948 ml) Maintain level at bottom of fill
hole threads. See page 95.
Demand Drive (Front Gearcase)
Demand Drive Fluid
9 oz. (265 ml) Maintain level at bottom of fill
hole threads. See page 97.
Front Prop Shaft Yoke
U-Joint Grease --- Grease fittings (3 pumps
maximum) every 500 miles, before long periods of storage, or after pressure washing or submerging.
Front Prop Shaft Yoke
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MAINTENANCE
Engine Oil
Oil Recommendations
Always change the oil filter whenever changing oil. POLARIS recommends the use of POLARIS PS-4 Full Synthetic 5W-
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 5W­50 oil. Follow the manufacturer's recommendations for ambient temperature operation. See page 144 for the part numbers of POLARIS products.
NOTICE: Mixing brands or using a non-recommended oil may cause serious
engine damage. Always use the recommended oil. Never substitute or mix oil brands.
Lubricant Capacity Drain Plug Torque
PS-4 5W-50 4-Cycle Oil 2 qts. (1.9 l) 14-17 ft-lbs (19-23 Nm)
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MAINTENANCE
Engine Oil
Oil Level
Access the oil dipstick and fill tube from the right side of the ATV.
A rising oil level between checks in cool weather driving can indicate contaminants such as gas or moisture collecting in the crankcase. If the oil level is over the full/safe mark, change the oil immediately.
1. Position the vehicle on a level surface.
2. Remove the dipstick. Wipe it
dry with a clean cloth.
3. Reinstall the dipstick
completely.
4. Remove the dipstick and
check the oil level. Maintain the oil level in the safe range. Do not overfill.
Safe Add Oil
Safe Range
Dipstick
Dipstick
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MAINTENANCE
Engine Oil
Oil and Filter Change
Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 86. 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.
3. Stop the engine.
4. Clean the area around the drain
plug.
5. Place a drain pan under the crank
case.
6. Remove the drain plug. Allow the
oil to drain completely.
CAUTION! Hot oil can cause burns to skin. Do not allow hot oil to contact s kin .
7. Install a new sealing washer on
the drain plug. The sealing surfaces on drain plug and crankcase should be clean and free of burrs, nicks or scratches.
8. Reinstall the drain plug. T orque to
14-18 ft-lbs (19-24 Nm).
9. Place shop towels beneath the oil
filter. Using an oil filter wrench (available from your POLARIS dealer), turn the filter counter­clockwise to remove it.
10. Using a clean dry cloth, clean the
filter sealing surface on the crankcase.
Oil
Filter
Drain Plug
Front View of the Engine
Oil Filter
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MAINTENANCE
Engine Oil
Oil and Filter Change
11. Lubricate the o-ring on the new filter with a film of fresh engine oil. Check to make sure the o-ring is in good condition.
12. Install the new filter and rotate it clockwise by hand until the filter gasket contacts the sealing surface, then turn it an additional 1/2 turn.
13. Remove the dipstick.
14. Add two quarts (1.9 l) of recommended oil.
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper mark on the dipstick.
21. Dispose of used filter and oil properly.
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MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 86. Maintain the oil level at the bottom of the fill plug hole threads. See page 144 for the part numbers of POLARIS products.
The fill plug is located on the left side of the ATV, under the rear fender, behind the wheel. The drain plug is located on the right side of the gearcase, on the right side of the ATV, behind the wheel well.
Transmission Oil Recommendations
Lubricant Cap acit y Fill Plug
Torque
Drain Plug
Torque
AGL Gearcase Lubricant &
Transmission Fluid
32 oz.
(946 ml)
20-25 ft-lbs (27-34 Nm)
20-25 ft-lbs
(27-34 Nm)
Drain Plug
Check/Fill Plug
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MAINTENANCE
Transmission Oil
Oil Check
1. Position the vehicle on a level
surface.
2. Remove the fill plug. Check the oil level.
3. Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to specification.
Oil Change
1. Remove the fill plug.
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 specification.
4. Add the proper amount of the recommended oil.
5. Reinstall the fill plug. Torque to specification.
6. Check for leaks.
7. Dispose of used oil properly.
Front Gearcase (Demand Drive) Fluid
Always check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 86. Maintain the fluid level at the bottom of the fill hole threads. See page 144 for the part numbers of POLARIS products.
Change the front gearcase fluid every 25 hours if the ADC unit is exposed to extreme use. Extreme use includes any of the following:
• operation in ADC mode for prolonged periods
• constant ADC operation on hilly or mountainous terrain
• ADC is the primary mode of all-wheel-drive operation
Tip: If the front gearcase makes excessive noise during ADC operation, change
the demand drive fluid. If the noise continues, please see your POLARIS dealer for service.
Fill Level
Fill Plug
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MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Recommendations
Use the recommended fluid. Use of other fluids may result in improper operation of components. Maintain the fluid level at the bottom of the fill hole threads.
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 demand drive 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).
Fluid Change
1. Position the vehicle on a level surface. Remove the fill plug. Place a drain pan under the demand drive unit.
2. Remove the drain plug. Allow the fluid to drain completely.
3. Clean and reinstall the drain plug. Torque to 11 ft-lbs (15 Nm).
4. Add the recommended fluid. See page 97 for capacity. Maintain the
fluid level at the bottom of the fill hole threads.
5. Reinstall the fill plug. Torque to 8-10 ft-lbs (11-14 Nm).
6. Check for leaks. Dispose of used fluid properly.
Gearcase Lubricant Capacity Fill Plug
Torque
Drain Plug
Torque
Front
Gearcase
Demand Drive Fluid 9 oz.
(265 ml)
8-10 ft-lbs
(11-14 Nm)
11 ft-lbs
(15 Nm)
Drain Plug
Fill Plug
Fill Level
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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 Antifreeze 50/50 Premix. This antifreeze is already premixed and ready to use. Do not dilute with water. See page 144 for the part numbers of POLARIS products.
Recovery Bottle Coolant
The recovery bottle is located on the left side of the vehicle.
1. Remove the left side panel. See page 103.
2. Maintain the coolant level
between the minimum and maximum marks on the bottle (when the fluid is cool).
3. Add coolant as needed.
Recovery
Bottle
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