Polaris Offroad Vehicle 800 6X6 User Manual

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WARNING

The engine exhaust from this product contains

chemicals known to the State of California to cause

cancer, birth defects or other reproductive harm.

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WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our world-

wide family of Polaris owners. We proudly produce an exciting line of

utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles

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

ational vehicles manufactured in the world today. Many years of experi-

ence have gone into the engineering, design, and development of your

Polaris vehicle, making it the finest machine we’ve ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the Polaris Service Manual and should be

performed only by a Factory Certified Master Service Dealer (MSD)

Technician.

Your Polaris dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your ser-

vice needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and acces-

sories, available through our online store at www.purepolaris.com. Have

your accessories and clothing delivered right to your door!

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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-

tries Inc.

based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrep-

ancies may result between the actual vehicle and the information presented in this publi-

cation. Depictions and/or procedures in this publication are intended for reference use

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

Printed in U.S.A.

2009 Sportsman 800 6X6 Owner’s Manual

P/N 9922027

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TABLE OF CONTENTS

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

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

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

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

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

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

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

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

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

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

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 131

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

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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 sym-

bols are used. Become familiar with their meanings before reading the

manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in

minor or moderate injury.

NOTICE

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

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

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INTRODUCTION

WARNING

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. This Polaris vehicle is not a toy and can be

hazardous to operate. This vehicle handles differently than other vehicles, such

as motorcycles and cars. A collision or rollover can occur quickly, even during

routine maneuvers like turning, or driving on hills or over obstacles, if you fail to

take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating this vehicle. Keep this manual with the

vehicle.

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

Purchasers of a new Polaris vehicle and their eligible family members are

entitled to take the ATV RiderCourse^sm. Contact ATV Enrollment Express at

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

ATV RiderCourse^sm.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age.

• Never permit a guest to operate this vehicle unless the guest has read this

manual and all product labels and has completed a certified safety training

course.

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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.

Engine Serial Number

####

VIN

Key Number

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

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SAFETY

Safety Training

Safety training is a top priority for Polaris. When you purchased your

new vehicle, your dealer instructed you on the authorized ATV Rider-

Course^smavailable to you and your eligible family members. This train-

ing is included in the purchase price of your vehicle. Polaris strongly

encourages you and your eligible family members who will be riding

this vehicle to take the ATV RiderCourse^sm. 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 vehicle, you can take the ATV Rider-

Course^smby calling ATV Enrollment Express at (800) 887-2887 or by

visiting www.atvsafety.org. Purchasers of a used Polaris vehicle will be

charged for this training.

This Polaris vehicle is an off-road vehicle. Familiarize yourself with all

laws and regulations concerning the operation of this vehicle in your

area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your vehi-

cle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY, call the Con-

sumer Product Safety Commission at 1-800-638-2772, or visit

www.cpsc.gov, visit www.atvsafety.org, or call Polaris at 1-800-342-

3764.

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SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding this vehicle. Wear pro-

tective clothing for comfort and to reduce the chance of injury.

Helmet

Eye Protection

Long

Sleeves

Gloves

Long Pants

Boots

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

Polaris vehicle, always wear a helmet that meets or exceeds established

safety standards.

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

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

051039

0006.31

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SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. When-

ever 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 vehi-

cle any equipment that may increase the speed or power of the vehicle,

or make any other modifications to the vehicle for these purposes.

The warranty on your Polaris vehicle is terminated if any equipment has

been added to the vehicle, or if any modifications have been made to the

vehicle, that increase its speed or power.

The addition of certain accessories, including (but not limited to) mow-

ers, blades, tires, sprayers, or large racks, may change the handling char-

acteristics of the vehicle. Use only Polaris-approved accessories, and

familiarize yourself with their function and effect on the vehicle.

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SAFETY

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction

increases the risk of an accident. The operator

must understand how to operate the vehicle

properly in different situations and on different

types of terrain.

Beginning and inexperienced operators should

complete the recommended safety training before

operating this vehicle. See page 7.

Never permit a guest to operate the vehicle unless

the guest has read this manual and all product

labels and has completed a certified safety training

course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY.

Operation is prohibited for anyone under 16 years

of age.

Even though a child may be within the

recommended age group for operating some

Polaris vehicles, he/she may not have the skills,

abilities, or judgment needed to operate this

vehicle safely and could be susceptible to accident

or injury.

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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 refu-

eling is performed or where gasoline is stored.

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

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

and water and change clothing.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or

death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm. Operate this vehicle only

outdoors or in well-ventilated areas.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in

safe operating condition before operating

increases the risk of an accident.

Always inspect the vehicle before each use to

make sure it's in safe operating condition.

Always follow all inspection and maintenance

procedures and schedules described in the

owner's manual.

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SAFETY

Safety Warnings

Protective Apparel

Riding in this vehicle without wearing an

approved helmet and protective eyewear

increases the risk of a serious injuries in the

event of an accident.

Operator and passenger must always wear an

approved helmet that fits properly and eye

protection (goggles or face shield).

Using Alcohol or Drugs

Operating the vehicle after consuming

alcohol or drugs could adversely affect

operator judgment, reaction time,

balance and perception.

Never consume alcohol or drugs before

or while operating this vehicle.

Carrying a Passenger

Carrying a passenger greatly reduces the

operator's ability to balance and control the

vehicle, which may result in an accident or

overturn.

Never carry a passenger on this vehicle.

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SAFETY

Safety Warnings

Operating on Pavement

Operating this vehicle on paved surfaces

(including sidewalks, paths, parking lots and

driveways) may adversely affect the

handling of the vehicle and could result in

loss of control and accident or overturn.

Avoid operating the vehicle on pavement.

The tires are designed for off-road use. If it's

unavoidable, travel slowly and avoid sudden

turns or stops.

Operating on Public Roads

Operating this vehicle on public streets,

roads or highways could result in a collision

with another vehicle.

Never operate the vehicle on any public

street, road or highway, including dirt and

gravel roads. In many states it's unlawful to

operate this type of vehicle on public

streets, roads and highways.

Operating at Excessive

Speeds

Operating the vehicle at excessive speeds

increases the operator's risk of losing

control.

Always operate at a speed that's

appropriate for the terrain, the visibility and

operating conditions, and your experience.

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SAFETY

Safety Warnings

Physical Control of the Vehicle

Removing a hand from the handlebars or

feet from the footrests during operation can

reduce your ability to control the vehicle or

cause loss of balance and ejection from the

vehicle. If the operator's foot is not firmly

planted on the footrest, it could also contact

the rear wheels.

Never remove your hands from the

handlebars while operating, and always

keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of

traction, loss of control, accident or overturn.

Always follow proper procedures for turning

as described in the owner's manual.

Never turn abruptly or at sharp angles. Never

turn at high speeds. Practice turning at slow

speeds before attempting to turn at faster

speeds.

Jumps and Stunts

Attempting wheelies, jumps and other

stunts increases the risk of an accident or

overturn.

Never attempt wheelies, jumps, or other

stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of

control or overturn. Always follow proper

procedures for climbing hills as described in

the owner's manual. See page 55. Always

move the 4X4 switch to ADC 4X4 (if

equipped) before ascending or descending a hill.

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SAFETY

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss

of control or overturn.

• Always follow proper procedures for travel-

ing down hills as described in the owner's

manual. NOTE: A special technique is

required when braking while traveling down-

hill. See page 57.

• Always descend a hill with the transmission

in forward gear. Do not descend a hill with

the transmission in neutral. Always move the

4X4 switch to ADC 4X4 (if equipped) before

ascending or descending a hill. See page 36.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean

sharply to one side. Travel straight down the hill when possible.

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss

of control or overturn. Avoid crossing the side of any hill unless absolutely

necessary.

If crossing a hillside is unavoidable, always follow proper procedures as

described in the owner's manual. See page 56.

Never attempt to turn the vehicle around on any hill until you've mastered the

turning technique (on level ground) as described in the owner's manual. See

page 58.

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SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly

dismounting while climbing a hill could cause an

overturn.

• Always maintain a steady speed when climbing

a hill.

• Always move the 4X4 switch to ADC 4X4 (if

equipped) before ascending or descending a

hill. See page 36.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the service brakes.

• Lock the parking brake when fully stopped.

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

uphill.

• Turn the vehicle around and remount, following the procedure described in

the owner's manual. See page 58.

If the vehicle begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

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

gradually.

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

brake.

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

uphill.

• Turn the vehicle around and remount, following the procedure described in

the owner's manual. See page 58.

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SAFETY

Safety Warnings

Operating on Steep Hills

Operating on excessively steep hills could cause

an overturn.

Never operate on hills too steep for the vehicle or

for your abilities. Never operate the vehicle on hills

steeper than 25 degrees.

Operating on Slippery Terrain

Failure to use extra caution when operating on

excessively rough, slippery or loose terrain could

cause loss of traction, loss of control, accident or

overturn.

Do not operate on excessively rough, slippery or

loose terrain. Always use extra caution on rough,

slippery or loose terrain.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on

unfamiliar terrain could result in an accident or

overturn.

Unfamiliar terrain may contain hidden rocks,

bumps, or holes that could cause loss of control or

overturn.

Travel slowly and use extra caution when operating

on unfamiliar terrain. Always be alert to changing

terrain conditions.

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SAFETY

Safety Warnings

Improper Tire Maintenance

Operating this vehicle with improper

tires or with improper or uneven tire

pressure could cause loss of control or

accident.

Always use the size and type of tires

specified for your vehicle.

Always maintain proper tire pressure as

described in the owner's manual and

on safety labels.

Operating Over Obstacles

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

Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution

and always follow proper operating procedures as outlined in this manual. See

page 60.

Skidding or Sliding

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

unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra

caution to reduce the chance of skidding or sliding. Do not operate on

excessively slippery surfaces.

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SAFETY

Safety Warnings

Improper Cargo Loading

Overloading the vehicle or carrying/towing

cargo improperly may cause changes in

handling, which could cause loss of control or

an accident.

• Never exceed the stated load capacity for

this vehicle.

• Cargo should be properly distributed and

securely attached.

• Reduce speed when carrying cargo or pull-

ing a trailer. Allow a greater distance for

braking.

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

ing a trailer.

Operating Improperly in Reverse

Improperly operating in reverse could result in a collision with an obstacle or

person. Always follow proper operating procedures as outlined in this manual.

See page 61.

Before shifting into reverse gear, always check for obstacles or people behind

the vehicle. When it's safe to proceed, back slowly.

Poor Visibility

Operating the vehicle in darkness or inclement weather could result in a collision

or accident, especially if operating on a road or street. This vehicle is not

equipped with highway-approved lights. Operate this vehicle off-road only. Use

caution and drive at reduced speeds in conditions of reduced visibility such as

fog, rain and darkness. Clean headlights frequently and replace burned out

headlamps promptly.

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SAFETY

Safety Warnings

Operating Through Deep Water

Operating the vehicle through deep or

fast-flowing water could cause the tires to

float, causing loss of control or overturn.

Avoid operating the vehicle through deep

or fast-flowing water. If it's unavoidable to

enter water that exceeds the

recommended maximum depth (see page

59):

• Travel slowly.

• Balance your weight carefully.

• Avoid sudden movements.

• Maintain a slow and steady forward motion. Do not make sudden turns or

stops, and do not make sudden throttle changes.

• Wet brakes may have reduced stopping ability. After leaving water, test the

brakes. Apply them lightly several times while driving slowly. The friction will

help dry out the pads.

Operating on Frozen Bodies of Water

Operating on frozen bodies of water may result

in serious injury or death if the vehicle and/or

the operator fall through the ice.

Never operate the vehicle on a frozen body of

water.

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SAFETY

Safety Warnings

Operating a Damaged Vehicle

Operating a damaged vehicle can result in an accident. After any overturn or

accident, have a qualified service dealer inspect the entire machine for possible

damage, including (but not limited to) brakes, throttle and steering systems.

Physical Skills

Safe operation of this rider-active vehicle requires good judgement and physical

skills. Persons with cognitive or physical disabilities who operate this vehicle

have an increased risk of overturn and loss of control.

Hot Exhaust Systems

Exhaust system components are very hot during and after use of the vehicle.

Hot components can cause burns and fire. Do not touch hot exhaust system

components. Always keep combustible materials away from the exhaust

system. Use caution when traveling through tall grass, especially dry grass.

Unauthorized Use of the Vehicle

Leaving the keys in the ignition can lead to unauthorized use of the vehicle,

which could result in an accident or overturn. Always remove the ignition key

when the vehicle is not in use.

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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 of the labels on the vehicle carefully. If

any of the labels depicted in this manual differ from the labels on your

vehicle, always read and follow the instructions of the labels on the

vehicle.

If an informational or graphic label becomes illegible or comes off, con-

tact your Polaris dealer to purchase a replacement. Replacement safety

labels are provided by Polaris at no charge. The part number is printed

on the label.

General Warning

WARNING

Improper vehicle use can result in SEVERE INJURY or DEATH

NEVER:

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

• Carry passengers. Passengers affect balance and steering and increase risk

of losing control.

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

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

• Operate this vehicle on HILLS steeper than 25 degrees. To prevent flipover

on hilly terrain, use throttle and brakes gradually.

ALWAYS:

• Use an approved HELMET AND PROTECTIVE GEAR.

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

• Use proper RIDING TECHNIQUES to avoid vehicle overturns on hills and

rough terrain and in turns.

• Use OVERRIDE for reverse speed limiter with caution. To prevent loss of

control, never activate override button with open throttle.

REVERSE operation can be dangerous, even at low speeds. Steering becomes

difficult. To prevent flipover, avoid sharp turns.

PARKING BRAKE may relax when used for more than 5 minutes. When parking

on grades, leave shift in forward.

LOCATE AND READ OWNER'S MANUAL. FOLLOW ALL INSTRUCTIONS

AND WARNINGS. IF OWNER'S MANUAL IS MISSING, CONTACT A POLARIS

DEALER FOR A REPLACEMENT.

7175784

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SAFETY

Safety Labels and Locations

Reverse Override

Warning

General

Warning

Tire Pressure/Load

Warning

Front Rack

Warning

Tire Pressure/Load Warning

WARNING

Improper tire pressure or overloading can cause loss of control.

Loss of control can result in severe injury or death.

• Cold tire pressure:

Front: 7.0 psi (48.3 kPa)

Center: 10.0 psi (68.9 kPa)

Rear:

10.0 psi (68.9 kPa)

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

7175651

Front Rack/Box Warning

WARNING

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

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

• Max. Rack Loads: 100 lbs. (45 kg)

7175662

Reverse Override Warning

WARNING

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

injury or death. Do not activate override while throttle is engaged. Always apply

throttle gradually, while in reverse.

7175486

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SAFETY

Safety Labels and Locations

Age 16 Warning

Container/No Passenger

Warning

Clutch Cover

Warning

Container/No Passenger Warning

WARNING

Remove flammable containers from box before refueling.

WARNING

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

• Never carry passengers.

Maximum Box Load 800 lbs. (363 kg)

7079316

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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 your chance of

severe injury or death.

NEVER operate this ATV if you are under age 16.

7172588

Clutch Cover Warning

WARNING

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

operate vehicle with guard removed.

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

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

death.

NO STEP

7172563

Hitch Capacity Label

TRAILER MAX WEIGHT:

1500 LBS. (682 KG) ON LEVEL GROUND

850 LBS. (386 KG) UP TO 15° GRADE

HITCH MAX. VERTICAL WEIGHT: 150 LBS. (68 KG)

9921509

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FEATURES AND CONTROLS

Switches

Headlight

Switch

4X4

Switch

Main Key Switch

Mode/Reverse

Override

Switch

Engine

Stop Switch

Mode/Reverse Override Switch

This vehicle is equipped with a reverse speed limiter system.To gain

additional wheel speed while backing, release the throttle and depress

the override button.

WARNING! Pressing the override button while the throttle is open can cause

loss of control, which may result in serious injury or death. Always release the

throttle before pressing the override button.

The override switch also allows activation of 4X4 in reverse, if the 4X4

switch is on. This switch is also used to toggle through the modes of the

rider information center. See page 37.

All Wheel Drive (AWD) Switch

See page 34 for AWD information.

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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.

OFF

RUN

OFF

Both the main switch and the engine stop switch will shut off all electri-

cal power to the vehicle, including lights.

Main Key Switch

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

cedures.

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.

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FEATURES AND CONTROLS

Throttle Lever

WARNING

Operating this vehicle with sticking or improperly operating throttle controls

could cause an accident. Never start or operate the vehicle if it has a sticking or

improperly operating throttle. Always contact your dealer for service before

operating the vehicle.

Failure to check or maintain proper operation of the throttle system can result in

an accident if the throttle lever sticks during operation. Always check the lever

for free movement and return before starting the engine. Also check

occasionally during operation.

Modifications to the electronic throttle control could result in failure to perform as

designed, which could result in an accident. Do not attempt to modify the throttle

control system or replace it with any after market throttle mechanisms. Always

ensure that the throttle cable is installed and properly routed to the throttle

control.

Engine speed and vehicle move-

ment are controlled by pressing the

throttle lever. The throttle lever is

spring loaded. Engine speed returns

to idle when the lever is released.

This vehicle is equipped with

Polaris Electronic Throttle Control

(ETC), which is designed to reduce

the risk of a frozen or stuck throttle.

If the throttle cable should stick in

an open position when the operator releases the throttle lever, the engine

will stop, and power to the rear wheels will cease.

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FEATURES AND CONTROLS

Brake Systems

WARNING

Aggressively applying the rear brake when backing down a hill may cause rear

tipover, which could result in serious injury or death. Never back down a hill.

Use caution when applying the rear brake. Do not aggressively apply the rear

brake when going forward. The rear wheels may skid and slide sideways,

causing loss of control, which may result in serious injury or death.

WARNING

Operating the vehicle with a spongy brake lever can result in loss of braking,

which could cause an accident. Never operate the vehicle with a spongy-feeling

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

The braking system is controlled by the two brake levers located on the

handlebars. The service brake (left lever) is an all-wheel brake. Use the

service brake for normal braking. The auxiliary brake (right lever) is a

middle axle rear brake only.

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FEATURES AND CONTROLS

Brake Systems

Service Brake Lever

Squeeze the service brake lever

(left lever) toward the handlebar to

apply the front and rear brakes.

These brakes are hydraulically acti-

vated disc brakes.

Always test brake lever travel and

master cylinder fluid level before

riding. When squeezed, the lever

should feel firm. Any sponginess

would indicate a possible fluid leak or low master cylinder fluid level,

which must be corrected before riding. Contact your dealer for proper

diagnosis and repairs.

Auxiliary Brake Lever

Squeeze the auxiliary brake lever (right lever) toward the handlebar to

apply the middle axle (rear brake) only.

Use the auxiliary brakes for addi-

tional braking or for backup if the

service brake system fails.

If the rear wheels slide while

using the auxiliary brake, reduce

brake lever pressure to brake the

rear wheels without skidding.

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FEATURES AND CONTROLS

Master Cylinder/Brake Fluid

WARNING

An over-full master cylinder may cause brake drag or brake lock-up, which could

result in an accident. Maintain brake fluid at the recommended level. Do not

overfill.

Never store or use a partial bottle of brake fluid. Brake fluid is hygroscopic,

meaning it rapidly absorbs moisture from the air. The moisture causes the

boiling temperature of the brake fluid to drop, which can lead to early brake fade

and the possibility of brake failure, which could result in an accident. After

opening a bottle of brake fluid, always discard any unused portion.

The master cylinders are located on the left and right handlebars. Check

the fluid levels of both master cylinders before each use of the vehicle.

Indicator Windows

Master Cylinders

1. Position the vehicle on a level surface.

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

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

of the master cylinder. The eye will appear dark when the fluid level

is full. When fluid is low, the eye will be clear.

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

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FEATURES AND CONTROLS

Parking Brake

Locking the Parking Brake

1. Place the transmission in

park.

2. Squeeze and release the brake

lever two or three times, then

squeeze and hold.

3. Push the parking brake lock

forward to engage the lock.

4. Release the brake lever.

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

lever. It will return to its unlocked position.

WARNING! Operating the vehicle while the parking brake is engaged could

result in an accident or fire. Always check to be sure the parking brake is

disengaged before operating.

The parking brake may relax if left on for a long period of time. Always

block the wheels to prevent rolling. Always block the wheels on the

downhill side of the vehicle if leaving it parked on a hill. Another option

is to park the vehicle in a sidehill position. Never depend on the parking

brake alone if the vehicle is parked on a hill. Always block the wheels to

prevent rolling.

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FEATURES AND CONTROLS

Automatic Transmission Gear Selector

The transmission gear selector is located

on the right side of the vehicle.

Gear

Selector

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.

Always place the transmission in park and lock the parking brake when-

ever the vehicle is left unattended.

Belt Life

To extend belt life, use low forward gear in heavy pulling situations and

when operating at less than 7 mph (11 km/h) for extended periods of

time.

Fuel Tank

Fuel Tank Cap

Always refuel with the engine

Cap

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

E-85 fuel.

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FEATURES AND CONTROLS

All Wheel Drive (AWD) System

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

ADC 4X4 Mode (if equipped)

When the switch is on ADC 4X4,

the ADC system allows engine

braking to all six wheels when the

vehicle descends a hill or incline.

Always move the 4X4 switch to

4X4

Switch

ADC 4X4 before ascending or

descending a hill. See page 36.

AWD Mode

When the switch is on 4X4, the vehicle is in all wheel drive, and the

AWD indicator light in the instrument cluster will be on.

When in AWD, the demand drive unit will automatically engage any

time the rear wheels lose traction. When the rear wheels regain traction,

the demand drive unit will automatically disengage.

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

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

on. See page 26.

2X4 Mode

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

times.

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FEATURES AND CONTROLS

All Wheel Drive System

Engaging AWD

The 4X4 switch may be turned on or off while the vehicle is moving.

Initially, the vehicle's electronic system will not enable AWD until the

engine RPM is below 3100. Once enabled, AWD remains enabled until

the 4X4 switch is turned off. If the switch is turned off while the demand

drive unit is moving, it will not disengage until the rear wheels regain

traction.

Engage the 4X4 switch before getting into conditions where front wheel

drive may be needed. If the rear wheels are spinning, release the throttle

before switching to AWD.

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

cause severe drive shaft and gearcase damage. Always switch to

4X4 or ADC 4X4 while the rear wheels have traction or are at rest.

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FEATURES AND CONTROLS

Active Descent Control (ADC) System

The ADC system (if equipped) allows engine braking to all four wheels

when the vehicle descends a hill or incline. Always move the 4X4

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

Engaging Active Descent Control

The ADC system will automatically engage when all four of the follow-

ing conditions occur:

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

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

• The throttle must be closed (throttle lever released)

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

Disengaging Active Descent Control

The ADC system will automatically disengage if at least one of the fol-

lowing conditions occur:

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

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

• The throttle is open (throttle is applied)

• The transmission is shifted to neutral or park

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FEATURES AND CONTROLS

Instrument Cluster

Your vehicle is equipped with an instrument cluster that senses vehicle

speed from the right front wheel. In addition to showing vehicle speed,

the speedometer needle flashes when a warning condition exists.

The instrument cluster measures distance in miles as well as hours of

operation. It also includes a reverse speed limiter function that limits the

vehicle's speed to approximately 7-9 mph (11-14 km/h). Refer to page

26 for additional information.

Speedometer

Needle

Speedometer

Rider

Information

Center

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

vehicle by hand or with a garden hose using mild soap.

Certain products, including insect repellents and chemicals, will

damage the speedometer lens and other plastic surfaces. Do not use

alcohol to clean the instrument cluster. Do not allow insect sprays to

contact the lens. Immediately clean off any gasoline that splashes on

the instrument cluster.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. All seg-

ments will light up for 2.5 seconds at start-up. If the instrument cluster

fails to illuminate, a battery over-voltage may have occurred and the

instrument cluster may have shut off to protect the electronic speedome-

ter. If this occurs, take the vehicle to your Polaris dealer for proper diag-

nosis.

1. Gear Indicator - This

indicator displays gear

shifter position.

H = High Gear

L = Low Gear

N = Neutral

R = Reverse Gear

P = Park

2. 4X4 Indicator - This

indicator illuminates

when the 4X4 switch is

on either ADC 4X4 or

4X4.

3. Engine Hour Display Indicator

4. Service Interval/Diagnostic Mode Indicator

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

that the vehicle is operating at an RPM too low to keep the battery

charged. It may also occur when the engine is at idle and high elec-

trical load (lights, cooling fan, accessories) is applied. Drive at a

higher RPM or recharge the battery to clear the warning.

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

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

in the fuel tank. When the last segment clears, a low fuel warning is

activated. All segments will flash, FUEL will display in the LCD,

and the speedometer needle will blink. Refuel immediately.

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

poses. The word HOT displays if the engine overheats. It also

appears if an EFI-related fault occurs. Do not operate the vehicle if

this warning appears. Serious engine damage could result.

9. Mode Indicator

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Standard Modes

Use the MODE button to toggle through the mode options. The reverse

override button is also the MODE button. See page 26. The transmission

cannot be in reverse when using this feature.

Odometer Mode

The odometer records the miles traveled by the vehicle.

Trip Meter Mode

The trip meter records the miles traveled by the vehicle on each trip if

it's reset before each trip. To reset the trip meter, select the trip meter

mode. Press and hold the mode button (override button) until the total

changes to 0. In the Rider Information Center, the trip meter display

contains a decimal point, but the odometer displays without a decimal

point.

Hour Meter Mode

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

Tachometer Mode

The engine RPM is displayed digitally. Small fluctuations in the RPM

from day to day may be normal because of changes in humidity, temper-

ature and elevation.

Clock Mode

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

40.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

The wrench icon will display when the gauge is in the diagnostic mode.

To exit the diagnostic mode, turn the key switch off and on. Any move-

ment of the tires will also cause the gauge to exit the diagnostic mode.

To enter the diagnostics mode:

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

2. Lock the parking brake.

3. Place the transmission in neutral.

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

Release the switch as soon as the display is activated.

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

Clock Screen

To reset the clock:

1. Enter the diagnostic mode.

2. Toggle to the clock screen.

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

Release the button.

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

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

quickly.

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

onds, until the minute display flashes.

6. Use the same procedure to reset the minutes.

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

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

new setting will not be locked into the memory.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Battery Voltage Screen

View this screen to check battery voltage level.

Tachometer Screen

View the tachometer to check engine speed.

4X4 Diagnostic Screen

The gauge indicates whether or not current is flowing through the all-

wheel-drive coil. This screen is for informational purposes only. Please

see your dealer for all major repairs.

Gear Circuit Diagnostic Screen

This screen displays the resistance value (in ohms) being read at the

gear switch input of the gauge. This screen is for informational purposes

only. Please see your dealer for all major repairs.

Programmable service interval

When the hours of engine operation equal the programmed service

interval setting, the wrench icon will flash for 5 seconds each time the

engine is started. When this feature is enabled, it provides a convenient

reminder to perform routine maintenance. See page 42.

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

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Diagnostic Mode

Programmable service interval

To enable or disable the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

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

preference.

To reset the service interval:

1. Enter the diagnostic mode.

2. Toggle to the service interval screen.

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

icon flashes. Release the button.

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

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

quickly.

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

until the hours cycle back to zero.

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

stops flashing. The new service interval is now programmed.

Miles/Kilometers toggle

The display in the tripmeter and odometer can be changed to display

either standard or metric units of measurement.

1. Enter the diagnostic mode.

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

(MP).

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

release the button once. When the display stops flashing, the mode

has been set.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

The EFI diagnostic mode is for informational purposes only. Please see

your Polaris dealer for all major repairs.

See page 45 for Blink Codes and Failure Descriptions. Use the follow-

ing procedure to download blink codes (failure codes) from the EFI

module.

1. Place the transmission in park.

2. Stop the engine.

3. Turn the key switch to the ON position.

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

then leave the switch on. Any blink code numbers stored in the EFI

module will display, one at a time, on the screen. The number “61”

and the word “END” displays after all codes have been transmitted.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

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.

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FEATURES AND CONTROLS

Instrument Cluster

Rider Information Center

Downloading Codes

Blink

Code

Failure Description

BEGIN SEQUENCE

Throttle Position Sensor Low

Throttle Position Sensor High

Throttle Position Sensor Out of Adjustment

Gear Sensor Signal

System Voltage Low

System Voltage High

Ignition Coil A Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

Ignition Coil A Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

Ignition Coil B Prim/Sec Circuit Malfunction: Open Load/Short-to-Ground

Ignition Coil B Prim/Sec Circuit Malfunction: Shorted Load/Short-to-Battery

Air Temp Sensor Low Voltage

Air Temp Sensor High Voltage

Engine Coolant Temp Low Voltage

Engine Coolant Temp High Voltage

Crank Position Sensor Circuit Fault

Barometric Pressure/Manifold Air Pressure Sensor Low

Barometric Pressure/Manifold Air Pressure Sensor High

IAC Stepper Motor: Open Load

IAC Stepper Motor: Short-to-Ground

Injector Circuit Malfunction - Cyl 1: Open Load/Short-to-Ground

Injector Circuit Malfunction - Cyl 1: Shorted Load/Short-to-Battery

Injector Circuit Malfunction - Cyl 2: Open Load/Short-to-Ground

Injector Circuit Malfunction - Cyl 2: Shorted Load/Short-to-Battery

MIL Circuit: Open Load/Short-to-Ground

MIL Circuit: Shorted Load/Short-to-Battery

Fuel Pump: Open Load/Short-to-Ground

Fuel Pump: Shorted Load/Short-to-Battery

Fan Circuit: Open Load/Short-to-Ground

Fan Circuit: Shorted Load/Short-to-Battery

ADC: Open Load/Short-to-Ground

ADC: Shorted Load/Short-to-Battery

Starter Enable: Open Load/Short-to-Ground

Starter Enable: Shorted Load/Short-to-Battery

Gear Sensor Signal

4X4: Open Load/Short-to-Ground

4X4: Shorted Load/Short-to-Battery

Rear Differential Enable: Open Load/Short-to-Ground (if equipped)

Rear Differential Enable: Shorted Load/Short-to-Battery (if equipped)

END SEQUENCE

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OPERATION

WARNING

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Read and

understand all safety warnings outlined in the safety section of this owner’s

manual.

Break-In Period

The break-in period for your new Polaris vehicle is the first ten hours of

operation, or the time it takes to use the first two full tanks of gasoline.

No single action on your part is as important as following the proce-

dures 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.

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OPERATION

Break-In Period

Engine and Drivetrain Break-in

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

extreme caution whenever handling gasoline.

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

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

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

iarize yourself with vehicle operation and handling.

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

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

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

6. Pull only light loads.

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

ever comes first.

PVT Break-in (Clutches/Belt)

A proper break-in of the clutches and drive belt will ensure a longer life

and better performance. Break in the clutches and belt by operating at

slower speeds during the break-in period as recommended. Pull only

light loads. Avoid aggressive acceleration and high speed operation dur-

ing the break-in period.

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OPERATION

Pre-Ride Checklist

Failure to inspect and verify that the vehicle is in safe operating condi-

tion before operating increases the risk of an accident. Always inspect

the vehicle before each use to make sure it's in safe operating condition.

Item

Remarks

Page

Brake system/lever travel

Ensure proper operation

Brake fluid

Ensure proper level

Auxiliary brake

ADC Fluid

Ensure proper operation

Ensure proper level

Front suspension

Rear suspension

Steering

Inspect, lubricate if necessary

Ensure free operation

Tires

Inspect condition and pressure

Inspect, ensure fastener tightness

Wheels/fasteners

Frame nuts, bolts, fasteners Inspect, ensure tightness

Fuel and oil

Ensure proper levels

Coolant level (if applicable)

Ensure proper level

Coolant hoses (if applicable) Inspect for leaks

Throttle

Ensure proper operation

117

Indicator lights/switches

Engine stop switch

Air filter, pre-filter

Air box sediment tube

Headlamp

Ensure operation

Ensure proper operation

Inspect, clean

Drain deposits whenever visible

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Brake light/tail lamp

Dump box latch

Riding gear

Check operation, apply Polaris dielec-

tric grease when lamp is replaced

Check condition and operation of the

mechanism

Wear approved helmet, goggles, and

protective clothing

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OPERATION

Safe Operation Practices

1. Complete the recommended safety training before operating this

vehicle. See page 7.

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

Do not allow anyone with cognitive or physical disabilities to oper-

ate this vehicle.

3. Never carry a passenger on this vehicle.

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

run in an enclosed area.

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

gency situations (if service brakes become inoperable).

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

pavement or on any public street, road or highway, including dirt

and gravel roads.

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

visibility such as fog, rain and darkness. Clean headlights fre-

quently and replace burned out headlamps promptly.

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

tions. Never operate at excessive speeds. Never attempt wheelies,

jumps, or other stunts. Never remove your hands from the handle-

bars while operating, and always keep both feet on the footrests.

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

cle.

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

Always maintain proper tire pressure.

11. Never operate a damaged vehicle. After any overturn or accident,

have a qualified service dealer inspect the entire machine for possi-

ble damage.

12. Never operate the vehicle on a frozen body of water.

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

bustible materials away from the exhaust system.

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

prevent unauthorized use.

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OPERATION

Know Your Riding Area/Tread Lightly

Familiarize yourself with all laws and regulations concerning the opera-

tion of this off-road vehicle in your area. Respect the environment in

which you ride. Find out where the designated riding areas are by con-

tacting 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 vehi-

cles 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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OPERATION

Starting the Engine

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

lated area.

2. Place the transmission in park.

3. Lock the parking brake.

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

is in gear and the brake is not engaged.

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

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

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

Activate the starter for a maximum of five seconds, releasing the

key when the engine starts.

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

wait five seconds before attempting to start again. Activate the

starter for another five seconds if necessary. Repeat this procedure

until the engine starts.

NOTICE: Operating the vehicle immediately after starting could cause engine

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

operating the vehicle.

Cold Weather Operation

If the vehicle is used year-round, check the oil level frequently. A rising

oil level could indicate the accumulation of contaminates such as water

or excess fuel in the bottom of the crankcase. Water in the bottom of the

crankcase can lead to engine damage and must be drained. Water accu-

mulation increases as outside temperature decreases.

See your Polaris dealer for engine heater kits, which provide quicker

warm-ups and easier starting in colder weather.

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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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OPERATION

Turning the Vehicle

Your vehicle is equipped

with a solid rear axle, which

drives both rear wheels

equally at all times. This

means that the wheel on the

outside of the turn must

travel a greater distance than

the inside wheel when turn-

ing and the inside tire must

slip traction slightly.

To turn, steer in the direction

of the turn, leaning your

upper body to the inside of

the turn while supporting

your weight on the outer

footrest. This technique

alters the balance of traction

between the rear wheels,

allowing the turn to be made

smoothly. The same leaning

technique should be used for

turning in reverse.

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

speeds.

WARNING! Turning improperly can result in vehicle overturn. Never turn

abruptly or at sharp angles. Never turn at high speeds.

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OPERATION

Driving on Slippery Surfaces

Turn in

direction of

skid

Sideways

skid

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.

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OPERATION

Driving Uphill

25° Maximum

Braking and handling are greatly affected when operating in hilly ter-

rain. Improper procedure could cause loss of control or overturn. When-

ever traveling uphill, follow these precautions:

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

ascending or descending a hill. See page 36.

2. Drive straight uphill.

3. Avoid steep hills (25° maximum).

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

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

6. Keep both feet on the footrests.

7. Shift body weight uphill.

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

throttle suddenly could cause the vehicle to flip over backwards.

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

include quick dismounting of the vehicle.

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OPERATION

Driving on a Sidehill (Sidehilling)

Driving on a sidehill is not recommended. Improper procedure could

cause loss of control or overturn. Avoid crossing the side of any hill

unless absolutely necessary.

If crossing a sidehill is unavoidable, follow these precautions:

1. Slow down.

2. Avoid crossing the side of a steep hill.

3. Shift body weight uphill.

4. Keep your feet on the footrests.

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

possible, or dismount on the uphill side immediately!

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OPERATION

Driving Downhill

When driving downhill, follow these precautions:

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

ascending or descending a hill. See page 36.

2. Avoid steep hills (25° maximum).

3. Shift body weight uphill.

4. Drive straight downhill.

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

loss of control.

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

may cause the rear wheels to lock, which could result in loss of con-

trol.

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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)

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

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

ascending or descending a hill. See page 36.

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

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

cle is pointing straight uphill.

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

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

slowly allow the vehicle to roll around to your right until it's point-

ing across the hill or slightly downward.

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

side, keeping body weight uphill.

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

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

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

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OPERATION

Driving Through Water

Your vehicle can operate

through water with a maximum

recommended depth equal to

the bottom of the footrests. Fol-

low 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.

Maximum

Depth

3. Avoid operating through

deep or fast-flowing 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 67. The following areas need

special attention: engine oil, transmission oil, demand drive fluid, rear

gearcase oil, and all grease fittings.

If the vehicle tips or overturns in water, or if the engine stops during or

after operating in water, restarting can result in serious engine

damage. Transport the vehicle to your dealer for service before

restarting the engine. If this is not possible, follow the vehicle

immersion inspection and drying procedures outlined on page 98,

then see your dealer for service at the first opportunity.

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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OPERATION

Driving Over Obstacles

Follow these precautions when operating over obstacles:

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

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

ards such as logs, rocks and low hanging branches.

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

terrain. Not all obstacles are immediately visible.

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

fallen trees.

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OPERATION

Driving in Reverse

Follow these precautions when operating in reverse:

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

2. Always avoid backing downhill.

3. Back slowly.

4. Apply the brakes lightly for stopping.

5. Avoid turning at sharp angles.

6. Never open the throttle suddenly.

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

required for vehicle movement. Use the override with caution as

rearward vehicle speed is greatly increased. Do not operate at wide

open throttle. Operate the throttle just enough to maintain a desired

speed.

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

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

damage.

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OPERATION

Hauling Cargo

WARNING

Overloading the vehicle or carrying or towing cargo improperly can alter vehicle

handling and may cause loss of control or brake instability, which can result in

serious injury or death. Always follow these precautions when hauling cargo:

• Never exceed the maximum weight capacity of the vehicle. When

determining the weight you are adding to the vehicle, include the weight of

the operator, accessories, loads in the rack or box and the load on the trailer

tongue. The combined weight of these items must not exceed the maximum

weight capacity.

• Reduce speed and allow a greater distance for braking.

• Cargo should be properly distributed and carried as low and forward in the

cargo box as possible.

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

• Use extreme caution when applying brakes with a loaded vehicle. Avoid

terrain or situations that may require backing downhill.

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

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

• Vehicle should never exceed 10 mph (16 km/h) while towing a load on a level

surface. Vehicle speed should never exceed 5 mph (8 km/h) when towing

loads in rough terrain, while cornering, or while ascending or descending a

hill.

Maximum Cargo Capacities (Level Ground)

Total Cargo

Front Rack Cargo

Cargo Box

900 lbs. (408 kg)

100 lbs. (45 kg)

800 lbs. (363 kg)

Maximum Towing Capacities

Towed Load (level ground)

Towed Load (up to 15° incline)

Vertical Hitch Weight

1500 lbs. (681 kg)

850 lbs. (386 kg)

150 lbs. (68 kg)

15°

Towing Grade

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OPERATION

Hauling Cargo

Load cargo as far

forward as possible

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

the vehicle, and never exceed the weight capacities outlined in the

specifications section of the owner's manual and on the safety

labels. The total load (operator, accessories, cargo and weight on

hitch) must not exceed the maximum weight capacity of the vehicle.

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

3. Always operate the vehicle with extreme caution whenever hauling

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

4. Slow down.

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

and operating. Unintentional box tilting will result if weight is

placed in the rear of the box and the latch is not secured.

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

NOTICE: Using an improper hitch or exceeding

the maximum tongue weight capacity

can result in serious damage to the

vehicle and will void your vehicle

Maximum

8.25" (21 cm)

warranty. Never install a hitch longer

than 8.25" (21 cm). Never install

automotive accessories on your

Polaris vehicle. Always install Polaris-

approved (or equivalent) accessories

designed for use on this vehicle.

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OPERATION

Hauling Cargo

Dumping Cargo

1. Select a level site to dump the cargo.

Do not attempt to dump or unload

the vehicle while parked on an

incline.

2. Lock the parking brake.

3. Dismount the vehicle.

4. Check cargo distribution. If cargo

has shifted to the rear of the box,

exercise caution.

WARNING! If the weight distribution in the

box is located toward the rear of the box

when the release lever is pulled forward, the

box may dump on its own, which could cause

serious injury. Never operate the dump lever

without checking the position of the load.

This will prevent unexpected dumping of the

cargo box. Never carry passengers in the

cargo box.

Latch

Release

Levers

5. Pull the cargo box release lever forward.

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

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

WARNING! Operating with the cargo box in the raised position can cause

serious injury and damage to the vehicle. The cargo box could close

unexpectedly and injure the driver. The rear tires will also catch the rear of the

box, damaging the vehicle and creating hazardous driving conditions. Never

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

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OPERATION

Parking on an Incline

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

precautions:

1. Stop the engine.

2. Place the transmission in park.

3. Lock the parking brake.

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

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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 arrestor that was tested and qualified to

be in accordance with the USDA Forest Service Standard 5100-1C. Fed-

eral law requires that this spark arrestor be installed and functional when

the vehicle is operated on public lands.

Operation of off-road vehicles on public lands in the U.S.A. is regulated

by 43 CFR 8343.1(c). Violations are subject to monetary penalties. Fed-

eral 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 com-

ponents are set at the factory for optimal performance and are not

adjustable.

The vehicle compliance labels can be found on the frame tubing of the

vehicle.

Electromagnetic Interference

This spark ignition system complies with Canadian ICES-002.

This vehicle complies with European directives 97/24/EC and 2004/

108/EC.

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MAINTENANCE

Periodic Maintenance Chart

Careful periodic maintenance will help keep your vehicle in the safest,

most reliable condition. Inspection, adjustment and lubrication of

important components are explained in the periodic maintenance chart.

Inspect, clean, lubricate, adjust and replace parts as necessary. When

inspection reveals the need for replacement parts, use genuine Polaris

parts available from your Polaris dealer.

Record maintenance and service in the Maintenance Log beginning on

page 131.

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 crank-

case. 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

WARNING

Improperly performing the procedures marked with a „ could result in

component failure and cause an accident, which may result in serious injury or

death. Always have an authorized Polaris dealer perform these services.

Maintenance Chart Key

X Perform these operations more often for vehicles subjected to severe

use.

Emission-related service (Failure to conduct this maintenance will

not void the emissions warranty but may affect emissions.)

„

Have an authorized Polaris dealer perform these services.

Perform all services at whichever maintenance interval is reached first.

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

Steering

Pre-Ride

Daily

Make adjustments as need

ed. See Pre-Ride Checklist

on page 48.

X Front suspension

X Rear suspension

Tires

X Brake fluid level

X Brake lever travel

Brake system

Wheels/fasteners

Frame fasteners

X Engine oil level

X Air filter, pre-filter

Inspect; clean often; replace

as needed

X Air box sediment

Daily

Drain deposits when visible

tube

Coolant

(if applicable)

Check level daily, change

coolant every 2 years

X ADC fluid (ADC

Check level daily, add as

needed

models)

Headlamp/taillight

Check operation; apply

dielectric grease if replacing

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Air filter,

Weekly

Monthly

1 M

Inspect; replace as needed

Inspect periodically

E main element

X Brake pad wear

10 H

20 H

60 (100)

X Engine oil change

125 (200) Perform a break-in oil change

(break-in)

Battery

20 H

25 H

Monthly

125 (200) Check terminals; clean; test

155 (250) Inspect level; change yearly

X Front gearcase

(demand drive) oil

X Middle gearcase

25 H

Monthly

155 (250) Inspect level; change yearly

oil (if equipped)

X Rear gearcase oil

(if equipped)

X Transmission oil

25 H

Monthly

155 (250) Inspect level; change yearly

155 (250) Inspect; clean if needed

X Engine breather

E filter (if equipped)

X General

50 H

3 M

310 (500) Lubricate all fittings, pivots,

cables, etc.

lubrication

Shift linkage

50 H

6 M

310 (500) Inspect, lubricate, adjust

310 (500) Lubricate

Steering

X Front suspension

310 (500) Lubricate

X Rear suspension

310 (500) Lubricate

Throttle Cable/

ETC Switch

310 (500) Inspect; adjust; lubricate;

replace if necessary

E Throttle Body

50 H

6 M

310 (500) Inspect duct for proper seal-

ing/air leaks

Intake Duct

X Front hub bear-

310 (500) Inspect; clean; replace as

needed

ings (if equipped)

Drive belt

310 (500) Inspect; adjust; replace as

needed

Cooling system

(if applicable)

620 (1000) Inspect coolant strength

seasonally; pressure test

system yearly

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MAINTENANCE

Periodic Maintenance Chart

Item

Maintenance Interval

Remarks

(whichever comes first)

Hours Calendar

Miles

(Km)

X Engine oil change 100 H

6 M

620 (1000) Perform a break-in oil change

at one month

X Oil filter change

100 H

6 M

620 (1000) Replace with oil change

620 (1000) Inspect; adjust

Valve clearance

12 M

Fuel system

100 H

12 M

620 (1000) Check for leaks at tank cap,

lines, filter, pump; replace

lines every two years

X Radiator (if

100 H

12 M

620 (1000) Inspect; clean external

surfaces

applicable)

X Cooling hoses

620 (1000) Inspect for leaks

(if applicable)

X Engine mounts

100 H

12 M

620 (1000) Inspect

Exhaust muffler/

pipe

Spark plug

100 H

12 M

620 (1000) Inspect; replace as needed

X Wiring

620 (1000) Inspect for wear, routing,

security; apply dielectric

grease to connectors

subjected to water, mud, etc.

Q Clutches (drive

100 H

200 H

12 M

24 M

620 (1000) Inspect; clean; replace worn

parts

and driven)

Q Shift selector

1240 (2000) Inspect; replace as needed

lubricant

Q Brake fluid

200 H

24 M

1240 (2000) Change every two years

Q ADC fluid

(ADC models)

X Fuel filter

200 H

24 M

1240 (2000) Check for leaks around lines.

Replace every 2 years, more

often under

extreme conditions.

Spark arrestor

300 H

36 M

1860 (3000) Clean out

Q Toe adjustment

Inspect periodically; adjust

when parts are replaced

X Auxiliary brake

Inspect daily; adjust as

needed

Headlight aim

Adjust as needed

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

E Emission-Related Service

„ Have an authorized Polaris dealer perform these services.

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MAINTENANCE

Lubrication Recommendations

Check and lubricate all components at the intervals outlined in the Peri-

odic Maintenance Chart beginning on page 67. Items not listed in the

chart should be lubricated at the General Lubrication interval.

The a-arms and lower control arms are lubricated at the factory, and no

additional lubrication will be needed. However, if these components are

subjected to severe use, grease zerks have been provided for additional

lubrication at the user's discretion.

Item

Lube

Method

Engine Oil

PS-4 PLUS Performance

Synthetic 2W-50

See page 72.

Brake Fluid

DOT 4 Only

See page 31.

Drive Chains

O-ring chain lube or

SAE 80/90

Lubricate as often as required

(before each ride in wet condi-

tions).

Gear Selector Oil

Transmission Oil

PS-4 PLUS Performance

Synthetic 2W-50

Maintain oil level at the center of

the shift rail. Do not overfill.

Polaris Premium Synthetic

Gearcase Lube

See page 75.

Front Gearcase

(Demand Drive) Oil

Demand Drive LT Premium See page 76.

Fluid

Middle Gearcase Oil Premium ATV Angle Drive

See page 79.

See page 78.

Fluid (or GL5 80-90 weight

Rear Gearcase Oil

gear lube)

ADC Fluid

Polaris ADC Fluid

See page 80.

Front Prop Shaft Yoke Polaris Premium U-Joint

Lube

Grease fittings (3 pumps maxi-

mum) every 500 miles, before long

periods of storage, or after pres-

sure washing or submerging

X = Perform more often for vehicles subjected to severe use

Front Prop Shaft Yoke

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MAINTENANCE

Engine Oil

Oil Recommendations

Polaris recommends the use of Polaris PS-4 PLUS Performance Syn-

thetic 2W-50 4-cycle oil or a similar oil for this engine. Oil may need to

be changed more frequently if Polaris oil is not used. Always use 2W-50

oil. Follow the manufacturer's recommendations for ambient tempera-

ture operation. See page 124 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.

Oil Level

Access the oil dipstick and fill tube

from the left side of the vehicle.

Dipstick

1. Position the vehicle on a level

surface.

2. Lift the lever lock to remove

the dipstick. Wipe it dry with a

clean cloth.

3. Reinstall the dipstick com-

pletely, but do not lock it. The

dipstick must be inserted com-

pletely to keep the angle and

depth of the stick consistent.

4. Remove the dipstick and check

the oil level. Maintain the oil

level in the safe range. Do not

overfill.

Tip: Due to the dipstick entry angle into

the crankcase, the oil level will

read higher on the bottom side of

the dipstick. Always read the level

on the upper surface of the dip-

stick.

Safe

Add Oil

Safe

Range

Check Level

on Top Side

5. After reinstalling the dipstick,

seat the lever lock.

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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 67. Always change the oil filter

whenever changing oil.

1. Position the vehicle on a level surface.

2. Start the engine.

Drain Plug Location

Allow it to warm up at

idle for two to three

minutes. Stop the

engine.

3. Clean the area around

the drain plug.

4. Place a drain pan

under the crankcase.

to front

5. Remove the drain

plug. Allow the oil to

drain completely.

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

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

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

or scratches.

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

8. Place shop towels beneath the oil

filter. Using an oil filter wrench

(available from your Polaris

dealer), turn the filter counter-

clockwise to remove it.

9. Using a clean dry cloth, clean the

filter sealing surface on the

crankcase.

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MAINTENANCE

Engine Oil

Oil and Filter Change

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

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

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

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

turn.

12. Remove the dipstick.

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

14. Place the transmission in park.

15. Lock the parking brake.

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

17. Stop the engine.

18. Check for leaks.

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

mark on the dipstick.

20. Dispose of used filter and oil properly.

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MAINTENANCE

Transmission Oil

Always check and change the

transmission oil at the intervals

outlined in the Periodic Mainte-

nance Chart beginning on page 67.

Maintain the oil level at the bottom

of the fill plug hole. The fill plug is

located on the right side of the

ATV behind the footwell. The

drain plug is located on the bottom

left side of the gearcase.

Fill Plug

We recommend the use of Polaris

Premium AGL Synthetic Gearcase

Lubricant. See page 124 for the

part numbers of Polaris products.

Fill Level

Drain Plug

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

Access the drain plug from the left side of the vehicle.

Oil Check

1. Position the vehicle on a level surface.

2. Remove the footwell (see page 86).

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

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

5. Reinstall the footwell.

Oil Change

1. Remove the footwell (see page 86).

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

the oil to drain completely.

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

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

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

6. Check for leaks.

7. Reinstall the footwell.

8. Dispose of used oil properly.

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MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Always check and change the demand drive fluid at the intervals out-

lined in the Periodic Maintenance Chart beginning on page 67. We rec-

ommend the use of Demand Drive LT Premium Fluid. Use of other

fluids may result in improper operation of components. See page 124 for

the part numbers of Polaris products.

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

for capacity.

Demand Drive Capacities

Demand Drive with ADC

9.3 oz. (275 ml)

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

drain plug is located on the bottom right side of the unit.

Fluid Check

1. Position the vehicle on a

Fill Plug

level surface. Remove

the fill plug. Check the

fluid level.

2. Add the recommended

fluid as needed to bring

the level to the bottom of

the fill hole threads.

Drain Plug

3. Reinstall the fill plug.

Torque to 8-10 ft. lbs.

(11-14 Nm).

Fill Level

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MAINTENANCE

Front Gearcase (Demand Drive) Fluid

Fluid Change

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

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

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

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

5. Add the recommended fluid.

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

7. Check for leaks.

8. Dispose of used fluid properly.

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MAINTENANCE

Rear Gearcase Oil

Always check and change the rear

gearcase oil at the intervals outlined in

the Periodic Maintenance Chart

beginning on page 67. Maintain the

fluid level at the bottom of the fill

hole threads. The oil capacity is 5 oz.

(150 ml). Do not overfill.

Fill Plug

The fill plug is located on the rear of

the gearcase. The drain plug is located

on the bottom of the gearcase.

Drain Plug

We recommend the use of Polaris ATV Angle Drive Fluid (or GL5 80-

90 weight gear lube). See page 124 for the part numbers of Polaris prod-

ucts.

Oil Check

1. Position the vehicle on a level surface.

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

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

of the fill hole threads. Do not overfill.

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

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain hole.

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

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

to 14 ft. lbs. (19 Nm).

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

Do not overfill.

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

7. Check for leaks.

8. Dispose of used oil properly.

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MAINTENANCE

Middle Gearcase Oil

Always check and change the mid-

dle gearcase oil at the intervals

outlined in the Periodic Mainte-

nance Chart beginning on page 67.

We recommend the use of Polaris

ATV Angle Drive Fluid (or GL5

80-90 weight gear lube). See page

124 for the part numbers of Polaris

products.

Drain Plug

The middle gearcase fill plug is

located on the side of the gearcase.

Maintain the oil level even with

the bottom thread of the fill plug

hole.

Check/Fill Plug

Oil Check

1. Position the vehicle on a level surface.

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

3. Add the recommended oil as needed.

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

Oil Change

1. Remove the fill plug.

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

oil into a drain pan. Discard used oil properly.

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

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

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

6. Check for leaks

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MAINTENANCE

Active Descent Control (ADC) Fluid

If your vehicle is equipped with Active Descent Control, there are two

fluid levels that must be maintained (demand drive fluid and ADC

fluid). See page 76 for demand drive fluid maintenance. Check and

change the ADC fluid level at the intervals outlined in the Periodic

Maintenance Chart beginning on page 67. Maintain the fluid level

between the minimum and maximum marks on the reservoir. We recom-

mend the use of Polaris ADC Fluid. See page 124 for the part numbers

of Polaris products.

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

the hydraulic system.

1. Open the front box cover and pull

open the access door.

2. View the fluid level in the reservoir.

3. If the level is below the minimum

mark, remove the cap and add the

recommended fluid.

4. Reinstall the cap. Secure the access

door. Secure the box cover.

ADC Fluid Reservoir

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MAINTENANCE

Active Descent Control (ADC) Fluid

Fluid Change

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

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

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

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

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

towel or suction tool to remove debris from the fluid and reservoir.

Debris in the reservoir may result in inadequate bleeding and

reduced performance of the system.

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

5. Remove the protective caps from the bleeder valves.

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

fluid and trapped air to flow from the fitting. Close the valve when

clean fluid begins to flow. Repeat this step for the remaining valve.

IMPORTANT: Close the bleeder valves before the reservoir fluid level drops

below the minimum fill line. Adding fluid to an empty reservoir will result in

trapped air. If the level drops below the minimum line, add fluid to the maximum

line and repeat step 6 before proceeding.

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

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

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

debris.

9. Reinstall the cap securely.

10. Clean up any drips or spills.

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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 con-

tracting (cooled) coolant is drawn back up from the bottle, past the pres-

sure cap, and into the radiator.

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

purging itself of trapped air. Check the coolant level and maintain as

recommended by adding coolant to the recovery bottle.

Polaris recommends the use of Polaris Premium 60/40 anti-freeze/cool-

ant or a 50/50 mixture of high quality aluminum compatible anti-freeze/

coolant and distilled water. Polaris Premium 60/40 is already premixed

and ready to use. Do not dilute with water. See page 124 for the part

numbers of Polaris products.

Always follow the manufacturer's mixing recommendations for the

freeze protection required in your area.

Recovery Bottle Coolant

The recovery bottle is located on

the left side of the vehicle.

1. Remove the left side panel.

See page 86.

2. Maintain the coolant level

between the minimum and

maximum marks on the bottle

(when the fluid is cool).

3. Add coolant as needed.

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MAINTENANCE

Cooling System

Radiator Coolant

To ensure that the coolant maintains its ability to protect the engine,

Polaris recommends that you drain the system completely every two

years and add a fresh mixture of antifreeze and water.

Replace the coolant any time the cooling system has been drained for

maintenance or repair. If the recovery bottle has run dry, check the level

in the radiator. Add coolant as needed.

CAUTION! Escaping steam can cause burns. Never remove the pressure cap

while the engine is warm or hot. Always allow the engine to cool before

removing the pressure cap.

1. Open the front box cover and

pull open the access door.

2. Remove the pressure cap.

3. Using a funnel, slowly add

coolant through the radiator

filler neck.

4. Reinstall the pressure cap. Use

of a non-standard pressure cap

will not allow the recovery

system to function properly.

Contact your dealer for the

correct replacement part.

Radiator Cap

5. Secure the access door.

6. Secure the box cover.

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MAINTENANCE

Brakes

Front/Rear/Middle Brakes

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

brakes are self-adjusting.

Under normal operation, the diaphragm extends into the reservoir as

fluid level drops. If the fluid level is low and the diaphragm is not

extended, a leak is likely and the diaphragm should be replaced. To

ensure proper diaphragm operation, always fill the reservoir as needed

whenever the cover is loosened or removed. Do not overfill.

WARNING! An over-full master cylinder may cause brake drag or brake lock-

up, which could result in serious injury or death. Maintain brake fluid at the

recommended level. Do not overfill.

The following checks are recommended to keep the brake system in

good operating condition. Check more often if brakes are used heavily

under normal operation.

1. Always keep brake fluid at an adequate

level. See page 31.

2. Check the brake system for fluid leaks.

3. Check the brakes for excessive travel or

spongy feel.

4. Check the friction pads for wear, damage

and looseness. Replace brake pads when

they are worn to 3/64" (1 mm).

3/64" (1 mm)

5. Check the security and surface condition

of the disc.

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MAINTENANCE

Toe Alignment

Use the following procedure to check the toe alignment of the vehicle.

The recommended toe alignment is 1/8" to 1/4" (3-6 mm) toe out.

WARNING! Severe injury or death can result from improper toe alignment and

adjustment. Do not attempt to adjust tie rod alignment. All tie rod adjustments

should be performed by an authorized Polaris dealer.

1. Position the vehicle on a

level surface.

2. Place the handlebars in a

straight-ahead position.

Stand

String

3. Tie a length of string between

two stands as shown in the

illustration. Position the

stands so that the string is

flush with the side of the rear

tire. If available, you may use

a long straight-edge instead

of string.

4. Measure the distance from

the string to the rim at the

front (1) and rear (2) of the

front rim. The rear

measurement should be 1/

16"-1/8" (2-3 mm) more than

the front measurement on

each side of the vehicle to

obtain the recommended 1/8"

to 1/4" (3-6 mm) toe out

alignment.

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

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

vice.

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MAINTENANCE

Steering Assembly

The steering assembly of the vehicle should be checked periodically for

loose nuts and bolts. If loose nuts and bolts are found, see your Polaris

dealer for service before operating the vehicle.

Side Panel Removal

1. Remove the seat.

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

motion, pull the panel outward to disengage the side panel from the

grommet. Pull the panel downward and rearward to remove it.

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

secure them.

Step 1

Step 2

Step 3

Footwell Removal

1. Remove the four screws on

Rivets

the bottom of the footwell.

2. Use a flat screwdriver or

sidecutters to remove the

plastic rivets securing the

footwell to the fenders.

3. Remove the footwell.

Screws

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MAINTENANCE

Tires

WARNING

Operating your vehicle with worn tires, improperly inflated tires, non-standard

tires or improperly installed tires will affect vehicle handling and could cause an

accident resulting in serious injury or death. Always follow all tire maintenance

procedures as outlined in this manual and on the labels on the vehicle. Always

use original equipment size and type when replacing tires.

Refer to the specifications section beginning on page 122 for recom-

mended tire type, size and pressure.

Tire Tread Depth

Always replace tires

when tread depth is

worn to 1/8" (3 mm)

or less.

1/8" (3 mm)

Front Wheel Hub Tightening

Front wheel bearing tightness and spindle nut retention are critical com-

ponent operations. All service must be performed by your authorized

Polaris dealer.

Wheel Removal

1. Stop the engine.

2. Place the transmission in park.

3. Lock the parking brake.

4. Loosen the wheel nuts slightly.

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

Polaris dealer.

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

footrest frame.

6. Remove the wheel nuts.

7. Remove the wheel.

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MAINTENANCE

Tires

Wheel Installation

1. Place the transmission in park.

2. Lock the parking brake.

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

and rotation arrows on the tire pointing toward forward rotation.

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

5. Lower the vehicle to the ground.

6. Torque the wheel nuts to specification.

WARNING! Loose nuts could cause a tire to come off during operation, which

could result in an accident or overturn. Always ensure that all nuts are torqued to

specification.

90 ft. lbs.

(122 Nm)

27 ft. lbs.

(37 Nm)

Cast Aluminum

Steel

Wheel Nut Torque Specifications

Check the wheel nut torques occasionally and when they've been loos-

ened for maintenance service.

Nut Type

Nut Torque

Lug Nut

90 ft. lbs. (122 Nm)

27 ft. lbs. (37 Nm)

2-Piece Flange Nut

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MAINTENANCE

Air Filter

1. Remove the seat.

Pre-Filter

2. Release the air box cover clips,

and remove the air box cover.

Main Filter

3. Loosen the clamp and remove

the filter.

4. Remove the fabric type pre-filter

from the main filter. Wash the

pre-filter in soapy water, then

rinse and let dry.

5. Reinstall the pre-filter over the

main filter. Install a new main

filter if needed.

6. Reinstall the filter into the air

box and tighten the clamp. Do

not over-tighten the clamp, as

filter damage could occur.

7. Reinstall the air box cover and

the seat.

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MAINTENANCE

Fuse Replacement

Fuse

Feature Supported

Speedometer

15A

20A

Electronic Fuel Injection

(Main Fuse) Ignition, Lighting

Accessories, 12V Power Receptacle

If the engine stops or will not start,

or if you experience other electrical

failures, a fuse may need replace-

ment. Locate and correct any short

circuits that may have caused the

blown fuse, then replace the fuse.

Spare fuses are provided in a com-

partment on the top of the access

door.

1. Open the front box cover and

pull open the access door.

2. Remove the suspect fuse from

the fuse panel. If the fuse is

blown, install a new fuse with

the same amperage.

Fuses

Fuse Panel

5or6 15 20 20

3. Secure the access door.

4. Secure the box cover.

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MAINTENANCE

Lights

Poor lighting can result in reduced visibility when driving. Headlight

and taillight lenses become dirty during normal operation. Clean lights

frequently and replace burned out lamps promptly. Always make sure

lights are adjusted properly for best visibility.

Upper Headlight Lamp Replacement

When servicing a halogen lamp, don't touch the lamp with bare fingers.

Oil from your skin leaves a residue, causing a hot spot that will shorten

the life of the lamp.

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

pod.

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

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

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

the speedometer.

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

before servicing.

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

connector, not on the wiring.

6. Turn the lamp counterclockwise to remove it.

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

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

8. Reassemble the pod.

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MAINTENANCE

Lights

High Beam Adjustment

The headlight beam can be adjusted slightly upward or downward. Use

the following procedure to make the adjustment.

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

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

25 ft.

(7.6 m)

2" (5 cm)

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

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

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

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

headlight beam should be two inches (5 cm) below the mark on the

wall. Include rider weight on the seat when measuring.

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

pod. Adjust the beam to the desired position by turning the knob

either clockwise or counterclockwise.

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MAINTENANCE

Lights

Low Beam Adjustment

Phillips Screw

The low beam can be adjusted

slightly upward or downward.

1. Loosen the phillips screw located

at the rear of the headlamp.

2. Tilt the headlamp upward or

downward.

3. Tighten the screw.

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MAINTENANCE

Lights

Headlight Housing Replacement

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

pod.

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

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

the speedometer.

4. Unplug the headlamp from the wiring harness.

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

mounting tabs.

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

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

8. Carefully pull the assembly up

and out of the pod.

9. Reverse the steps to install the

new housing and reassemble

the pod. The distance from the

headlamp parting line to the

end of the adjustment knob

stop is 5 1/8" (13 cm).

10. Adjust the headlight aim by

5 1/8"

turning the adjusting knob.

(13 cm)

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MAINTENANCE

Lights

Lower Headlamp Replacement

1. Turn the back of the headlight

harness counterclockwise and

pull the harness assembly away

from the headlight assembly.

2. Remove the headlamp and install

the new headlamp.

3. Reinstall the harness assembly

into the headlight assembly.

Harness

4. Turn the headlight harness clock-

wise to secure the headlamp.

Taillight/Brakelight Lamp Replacement

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

cover and gasket and set aside for reassembly.

2. Remove the lamp.

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

4. Test the light for proper operation.

5. Reinstall the gasket and lens cover.

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MAINTENANCE

Spark Plugs

Spark Plug Recommendations

Refer to the specifications section beginning on page 122 for the recom-

mended spark plug type and gap for your vehicle. Torque spark plugs to

specification.

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

damage. Always use Polaris-recommended spark plugs.

Plug Condition

Torque Specification

New Spark Plug

9-11 ft. lbs. (12-15 Nm)

17-20 ft. lbs. (23-27 Nm)

Previously Installed Spark Plug

Spark Plug Inspection

Spark plug condition is indicative of engine operation. Check the spark

plug firing end condition after the engine has been warmed up and the

vehicle has been driven at higher speeds. Immediately check the spark

plugs for correct color. See page 97.

CAUTION! A hot exhaust system and engine can cause burns. Wear

protective gloves when removing a spark plug for inspection.

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

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

spark plug counterclockwise to remove it.

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

cation.

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MAINTENANCE

Spark Plugs

Spark Plug Inspection

Normal Spark Plug

The normal insulator tip is gray, tan or light brown. There will be few

combustion deposits. The electrodes are not burned or eroded. This indi-

cates the proper type and heat range for the engine and the service.

The tip should not be flaky and white. A white insulator tip indicates

overheating, caused by use of an improper spark plug or incorrect fuel.

Wet Fouled Spark Plug

The wet fouled insulator tip is black. A damp oil film covers the firing

end. There may be a carbon layer over the entire nose. Generally, the

electrodes are not worn. General causes of fouling are excessive oil, use

of non-recommended oil or incorrect throttle body adjustments.

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MAINTENANCE

Vehicle Immersion

If your vehicle becomes immersed, major engine damage can result if

the machine is not thoroughly inspected. Take the vehicle to your dealer

before starting the engine. If it's impossible to take your vehicle to a

dealer before starting it, follow the steps outlined below.

1. Move the vehicle to dry land or at the very least, to water below the

footrests.

2. Check the air box. If water is present, dry the air box and replace the

filter with a new filter.

3. Remove the spark plugs.

4. Turn the engine over several times using the electric start.

5. Dry the spark plugs. Reinstall the plugs or install new plugs.

6. Attempt to start the engine. If necessary, repeat the drying proce-

dure.

7. Take the vehicle to your dealer for service as soon as possible,

whether you succeed in starting it or not.

8. If water has been ingested into the PVT, follow the procedure on

page 102 for drying out the PVT.

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MAINTENANCE

Spark Arrestor

WARNING

Failure to heed the following warnings while servicing the spark arrestor could

result in serious injury or death. Never run the engine in an enclosed area.

Remove any combustible materials from the area. Wear eye protection and

leather work gloves. Do not stand behind or in front of the vehicle while purging.

Never go under the vehicle while it's inclined.

The exhaust system can get extremely hot. Do not perform service on the spark

arrestor while the system is hot. Allow components to cool sufficiently before

proceeding.

Use the following procedure to periodically purge accumulated carbon

from the exhaust pipe/muffler.

1. Remove the arrestor clean-out

plug from the bottom of the

muffler. Be sure to clean out

Exhaust

Outlet

both arrestors if your model

has two.

2. Place the transmission in park.

3. Start the engine.

Clean-Out Plug

4. Quickly squeeze and release

the throttle lever several times

to purge carbon from the system.

5. If carbon comes out of the exhaust, cover or plug the exhaust outlet.

Wear protective gloves.

6. Lightly tap on the exhaust pipe with a rubber mallet while repeating

step 4.

7. If particles are still suspected to be in the muffler, elevate the rear of

the vehicle one foot (30 cm) higher than the front. Block the wheels.

8. Place the transmission in park. Lock the parking brake. Repeat steps

4 to 6 until no more particles are expelled.

9. Stop the engine. Allow the arrestor to cool.

10. Reinstall the arrestor plug and remove the exhaust outlet cover or

plug.

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MAINTENANCE

PVT System

WARNING

Failure to comply with the instructions in this warning can result in severe injury

or death.

Do not modify any component of the PVT system. Doing so may reduce its

strength so that a failure may occur at a high speed. The PVT system has been

precision balanced. Any modification will cause the system to be out of balance,

creating vibration and additional loads on components.

The PVT system rotates at high speeds, creating large amounts of force on

clutch components. Extensive engineering and testing has been conducted to

ensure the safety of this product. However, as the owner, you have the following

responsibilities to make sure this system remains safe:

• Always follow all recommended maintenance procedures. See your dealer as

outlined in the owner's manual.

• This PVT system is intended for use on Polaris products only. Do not install it

in any other product.

• Always make sure the PVT housing is securely in place during operation.

100

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MAINTENANCE

PVT System

The basic operation of the Polaris PVT system is dependent on engine

speed and vehicle torque requirements. As engine speed increases, the

force exerted on the movable drive sheave by the flyweights also

increases. This, in turn, increases the amount of pinch applied to the

drive belt. Similarly, if the engine speed decreases, the amount of cen-

trifugal force decreases, reducing the amount of belt pinch.

The approximate gear ratio difference between high and low range is

1:2.25. This difference in gearing affects the operation of the PVT, espe-

cially at speeds less than 7 MPH (11 km/h), due to the system's depen-

dence on engine speed.

For example, when operating at a ground speed of 3 MPH (5 km/h) in

low range, the engine speed would be around 3000 RPM. This is well

above the engagement speed of 1200 - 1400 RPM. However, in high

range at 3 MPH (5 km/h), the engine would be running at only 1500

RPM. Whenever operating this close to the engagement speed, the

engine may be running at a speed too low to provide the pinch needed to

prevent belt slip. Belt slip is responsible for creating the excessive heat

that destroys belts, wears clutch components and causes outer clutch

covers to fail.

The air temperature in the clutch cover is substantially reduced by using

low range while operating at low ground speeds. Reducing the tempera-

ture inside the clutch cover greatly extends the life of the PVT compo-

nents (belt, cover, etc.).

101

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MAINTENANCE

PVT System

When To Use Low Range and High Range

Condition

Range to Use

Operating at speeds less than 7 MPH (11 km/h)

Towing heavy loads

Low

High

Operating in rough terrain (swamps, mountains, etc.)

Operating at speeds greater than 7 MPH (11 km/h)

PVT Drying

There may be some instances when water is accidently ingested into the

PVT system. Use the following instructions to dry it out before operat-

ing.

1. Position the vehicle on a level surface.

2. Remove the drain plug. Allow the water to drain completely. Rein-

stall the drain plug.

3. Start the engine. Place the transmission in park.

4. Apply varying throttle for 10-15 seconds to expel the moisture and

air-dry the belt and clutches. Do not hold the throttle wide open for

more than 10 seconds.

5. Allow the engine RPM to settle to idle speed, then shift the trans-

mission to the lowest available range.

6. Test for belt slippage. If the belt slips, repeat the process.

7. Take the vehicle to your dealer for service as soon as possible.

102

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MAINTENANCE

Battery

WARNING

Improperly connecting or disconnecting battery cables can result in an explosion

and cause serious injury or death. When removing the battery, always

disconnect the negative (black) cable first. When reinstalling the battery, always

connect the negative (black) cable last.

WARNING

Battery electrolyte is poisonous. It contains sulfuric acid. Serious burns can

result from contact with skin, eyes or clothing.

Antidote:

External: Flush with water.

Internal: Drink large quantities of water or milk. Follow with milk of magnesia,

beaten egg, or vegetable oil. Call physician immediately.

Eyes: Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc. away.

Ventilate when charging or using in an enclosed space. Always shield eyes

when working near batteries. KEEP OUT OF REACH OF CHILDREN.

Your vehicle may have either a sealed battery, which requires little

maintenance, or a conventional battery. A sealed battery can be identi-

fied by its flat covers on the top of the battery. A conventional battery

has six filler caps on the top of the battery.

Always keep battery terminals and connections free of corrosion. If

cleaning is necessary, remove corrosion with a stiff wire brush. Wash

with a solution of one tablespoon baking soda and one cup water. Rinse

well with tap water and dry off with clean shop towels. Coat the termi-

nals with dielectric grease or petroleum jelly. Be careful not to allow

cleaning solution or tap water into a conventional battery.

103

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MAINTENANCE

Battery

Battery Removal

1. Remove the seat.

2. Disconnect the battery hold-down strap.

3. On conventional batteries, remove the battery vent tube.

4. Disconnect the black (negative) battery cable first.

5. Disconnect the red (positive) battery cable last.

6. Lift the battery out of the vehicle. Be careful not to tip a conven-

tional battery sideways, which could spill electrolyte.

NOTICE: If electrolyte spills, immediately wash it off with a solution of one

tablespoon baking soda and one cup water to prevent damage to the

vehicle.

104

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MAINTENANCE

Battery

Battery Installation

Using a new battery that has not been fully charged can damage the bat-

tery and result in a shorter life. It can also hinder vehicle performance.

Follow the battery charging instructions on page 107 before installing

the battery.

1. Ensure that the battery is fully charged.

2. Place the battery in the battery holder.

3. With conventional batteries, install the battery vent tube (sealed bat-

teries do not have a vent tube). The vent tube must be free of

obstructions and securely installed. Route the tube away from the

frame and vehicle body to prevent contact with electrolyte.

WARNING! Battery gases could accumulate in an improperly installed vent tube

and cause an explosion, resulting in serious injury or death. Always ensure that

the vent tube is free of obstructions and is securely installed as recommended.

4. On conventional batteries, coat the terminals with dielectric grease

or petroleum jelly.

5. Connect and tighten the red (positive) cable first.

6. Connect and tighten the black (negative) cable last.

7. Secure the battery hold-down strap.

8. Verify that cables are properly routed. Cables should be safely

tucked away at the front and rear of the battery.

105

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MAINTENANCE

Battery

Battery Storage

Whenever the vehicle is not used for a period of three months or more,

remove the battery from the vehicle, ensure that it's fully charged, and

store it out of the sun in a cool, dry place. Check battery voltage each

month during storage and recharge as needed to maintain a full charge.

Polaris recommends maintaining battery charge by using a Polaris Bat-

tery Tender charger or by charging about once a month to make up for

normal self-discharge. Battery Tender can be left connected during the

storage period, and will automatically charge the battery if the voltage

drops below a pre-determined point. See page 124 for the part numbers

of Polaris products.

Battery Fluid (Conventional Battery)

A poorly maintained battery will

Upper

Mark

Lower

Mark

deteriorate rapidly. Check the battery

fluid level often. Maintain the fluid

level between the upper and lower

level marks.

Add only distilled water. Tap water

contains minerals that are harmful to

a battery.

106

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MAINTENANCE

Battery

Battery Charging (Conventional Battery)

1. Remove the battery from the vehicle to prevent damage from leak-

ing or spilled electrolyte during charging. See page 104.

2. Charge the battery with a charging output no larger than 1/10 of the

battery’s amp/hr rating. Charge as needed to raise the specific grav-

ity to 1.270 or greater.

3. Reinstall the battery. See page 105. Make sure the positive terminal

is toward the front of the vehicle.

Battery Charging (Sealed Battery)

The following battery charging instructions apply only to the installa-

tion of a sealed battery. Read all instructions before proceeding with the

installation of this battery.

The sealed battery is already filled with electrolyte and has been sealed

and fully charged at the factory. Never pry the sealing strip off or add

any other fluid to this battery.

The single most important thing about maintaining a sealed battery is to

keep it fully charged. Since the battery is sealed and the sealing strip

cannot be removed, you must use a voltmeter or multimeter to measure

DC voltage.

WARNING! An overheated battery may explode, causing severe injury or

death. Always watch charging times carefully. Stop charging if the battery

becomes very warm to the touch. Allow it to cool before resuming charging.

Tip:

For a refresh charge, follow all instructions carefully.

1. Check the battery voltage with a voltmeter or multimeter. A fully

charged battery will register 12.8 V or higher.

2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps

or less until battery voltage is 12.8 or greater.

3. When using an automatic charger, refer to the charger manufac-

turer's instructions for recharging. When using a constant current

charger, use the guidelines on the next page for recharging.

107

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MAINTENANCE

Battery

Battery Charging (Sealed Battery)

Always verify battery condition before and 1-2 hours after the end of

charging.

Charge Time

State of

Charge

(Using constant current

Voltage

Action

charger @ standard amps

specified on top of battery)

100%

12.8-13.0 volts

None, check at 3

mos. from date of

manufacture

None required

75%-100%

12.5-12.8 volts

May need slight

charge, if no

3-6 hours

charge given,

check in 3 months

50%-75%

25%-50%

12.0-12.5 volts

11.5-12.0 volts

Needs charge

5-11 hours

At least 13 hours,

verify state of charge

0%-25%

11.5 volts or less Needs charge with

desulfating charger

At least 20 hours

108

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

Keeping your Polaris vehicle clean will not only improve its appearance

but it can also extend the life of various components.

NOTICE: High water pressure may damage components. Polaris recommends

washing the vehicle by hand or with a garden hose, using mild soap.

Certain products, including insect repellents and chemicals, will

damage plastic surfaces. Do not allow these types of products to

contact the vehicle.

The best and safest way to clean your Polaris vehicle is with a garden

hose and a pail of mild soap and water.

1. Use a professional-type washing cloth, cleaning the upper body first

and the lower parts last.

2. Rinse with clean water frequently.

3. Dry surfaces with a chamois to prevent water spots.

Washing Tips

• Avoid the use of harsh cleaners, which can scratch the finish.

• Do not use a power washer to clean the vehicle.

• Do not use medium to heavy duty compounds on the finish.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

109

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MAINTENANCE

Cleaning and Storage

Washing the Vehicle

If a high pressure water system is used for cleaning (not recommended),

exercise extreme caution. The water may damage components and could

remove paint and decals. Avoid directing the water stream at the follow-

ing items:

• Wheel bearings

• Radiator

• Transmission seals

• Cab and body panels

• Electrical components

• Switches and controls

• Fuel system components

• Labels and decals

If an informational or graphic label becomes illegible or comes off, con-

tact your Polaris dealer to purchase a replacement. Replacement safety

labels are provided by Polaris at no charge.

Grease all zerk fittings immediately after washing. Allow the engine to

run for a while to evaporate any water that may have entered the engine

or exhaust system.

Polishing the Vehicle

Polaris recommends the use of common household aerosol furniture

polish for polishing the finish on your Polaris vehicle. Follow the

instructions on the container.

Polishing Tips

• Avoid the use of automotive products, some of which can scratch the

finish of your vehicle.

• Always use clean cloths and pads for cleaning and polishing. Old or

reused cloths and pads may contain dirt particles that will scratch the

finish.

110

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MAINTENANCE

Cleaning and Storage

Chrome Wheel Care (if equipped)

Proper maintenance will protect chrome wheels from corrosion, pre-

serve wheel life and ensure a "like new" appearance for many years.

Chrome wheels exposed to road salt (or salt in the air in coastal areas)

are more susceptible to corrosion if not properly cleaned. Clean chrome

wheels more often if they're exposed to salt or other corrosive elements.

1. Wash chrome wheels frequently. Use a mild detergent. Never use

abrasive cleaners on plated or painted surfaces.

2. Rinse well with clear water. Soap, detergents, salt, dirt, mud and

other elements can cause corrosion.

3. Polish the clean chrome wheels periodically. Use an automotive

grade chrome polish.

4. Routinely and liberally apply a weather resistant wax to each pol-

ished chrome wheel. Choose a product suitable for chrome finishes.

Read and follow the product labels and instructions.

Removing Corrosion

If light rust is found on the chrome finish, use steel wool (#0000-OTT

grade) to remove it. Gently rub the affected areas with the steel wool

until the corrosion has been removed. Clean and polish the wheel as out-

lined above.

111

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MAINTENANCE

Cleaning and Storage

Storage Tips

NOTICE: Starting the engine during the storage period will disturb the

protective film created by fogging and damage could occur. Never

start the engine during the storage period.

Clean the Exterior

Make any necessary repairs and then clean the vehicle as recommended.

See page 109.

Stabilize the Fuel

1. Fill the fuel tank.

2. Add Polaris Carbon Clean Fuel Treatment or Polaris Fuel Stabilizer.

Follow the instructions on the container for the recommended

amount. Carbon Clean removes water from fuel systems, stabilizes

fuel and removes carbon deposits from pistons, rings, valves and

exhaust systems.

3. Allow the engine to run for 15-20 minutes to allow the stabilizer to

disperse through the entire fuel delivery system.

Oil and Filter

Change the oil and filter. See page 73.

Air Filter / Air Box

1. Inspect and clean (or replace) the pre-cleaner and air filter.

2. Clean the air box.

3. Drain the sediment tube.

112

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MAINTENANCE

Cleaning and Storage

Storage Tips

Fluid Levels

Inspect the following fluid levels. Change fluids as recommended in the

Periodic Maintenance Chart beginning on page 67.

• Demand drive unit (front gearcase)

• ADC fluid (ADC models) (change every two years)

• Rear gearcase

• Middle gearcase

• Transmission

• Brake fluid (change every two years and any time the fluid looks dark

or contaminated)

• Coolant (test strength)

Fog the Engine

1. Treat the fuel system with Polaris Carbon Clean, following the

instructions on the can. Run the engine for several minutes so the

Carbon Clean reaches the injectors. Stop the engine.

2. Remove the spark plugs and add 2-3 tablespoons of Premium 4 Syn-

thetic 0W40 engine oil. To access the plug holes, use a section of

clear 1/4" hose and a small plastic squeeze bottle filled with the pre-

measured amount of oil.

3. Reinstall the spark plugs. Torque to specification.

4. Apply dielectric grease to the inside of each spark plug cap and rein-

stall the caps onto the plugs.

5. Turn the engine over several times. Oil will be forced in and around

the piston rings and ring lands, coating the cylinder with a protec-

tive film of fresh oil.

6. If Polaris fuel system additive is not used, the fuel tank, fuel lines,

and injectors should be completely drained of gasoline.

113

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MAINTENANCE

Cleaning and Storage

Storage Tips

Inspect and Lubricate

Inspect all cables and lubricate all areas of the vehicle as recommended

in the Periodic Maintenance Chart beginning on page 67.

Battery Maintenance

Remove the battery and recharge it as outlined on page 107. Store the

battery in a cool, dry place.

Storage Area/Covers

Set the tire pressure and safely support the vehicle with the tires slightly

off the ground. Be sure the storage area is well ventilated. Cover the

vehicle with a genuine Polaris cover. Do not use plastic or coated mate-

rials. They do not allow enough ventilation to prevent condensation, and

may promote corrosion and oxidation.

Accessories

Auxiliary power outlets provide 12-volt power for operating accesso-

ries. Accessory outlets are available for all models. Polaris also has a

wide range of additional accessories available for your vehicle. Always

install accessories that are approved for use on this vehicle. Please see

your Polaris dealer.

114

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MAINTENANCE

Transporting the Vehicle

Follow these procedures when

transporting the vehicle.

1. Stop the engine.

2. Place the transmission in

park.

3. Lock the parking brake.

4. Secure the fuel cap, oil cap

and seat.

5. Always tie the frame of the

vehicle to the transporting

unit securely with suitable

straps or rope. Do not

attach tie straps to the front

A-arm bolt pockets, racks

or handlebars.

6. Remove the key to prevent

loss during transporting.

115

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ADJUSTMENTS

Camber and Caster

The camber and caster are non-adjustable.

Rear Springs

The rear shock absorber springs are

adjusted by rotating the adjusters either

clockwise or counterclockwise to increase

or decrease spring tension. Always adjust

all rear springs to equal settings.

Adjuster

Accessory springs are available through

your Polaris dealer.

Handlebars

The handlebars can be adjusted for rider

preference.

WARNING! Improper adjustment of the handlebars or incorrect torquing of the

adjuster block tightening bolts can cause limited steering or loosening of the

handlebars, resulting in loss of control and serious injury or death. Follow the

adjustment procedures exactly, or see your Polaris dealer for service.

1. Remove the upper headlight

pod.

2. Loosen the four handlebar

bolts.

3. Adjust the handlebar to the

desired height. Be sure the

handlebars do not contact the

gas tank or any other part of

the machine when turned fully

to the left or right.

4. Torque the front two bolts to

10-12 ft. lbs. (14-17 Nm), then

torque the rear two bolts. A

gap of up to 1/8" (3 mm) will

remain at the rear of the clamp

blocks.

Handlebar

Bolts

116

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ADJUSTMENTS

Throttle Body/Idle RPM

Idle RPM is preset by the manufacturer. If the engine idle speed is not

satisfactory, please see your Polaris dealer for adjustment.

Throttle Cable Freeplay

Adjust throttle cable freeplay at the handlebar.

1. Locate the throttle cable

adjuster at the handlebar.

2. Squeeze the end of the rub-

ber boot and slide it far

enough to expose the end of

the inline cable adjuster.

3. Loosen the adjuster lock nut.

4. Rotate the boot to turn the

adjuster until 1/16" to 1/8"

(1.5-3 mm) of freeplay is

achieved at the thumb lever.

While adjusting freeplay, be

sure to flip the throttle lever

back and forth.

Boot

5. Tighten the lock nut.

6. Squeeze the end of the rub-

ber boot and slide it over the

cable adjuster to its original

position.

Lock Nut

Adjuster

117

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TROUBLESHOOTING

Drive Belt Wear/Burn

Possible Cause

Solution

Driving onto a pickup or Use low range during loading.

tall trailer in high range

Starting out going up a

steep incline

Use low range or turn around using the K-turn (see page

58).

Driving at low RPM or

Drive at a higher speed or use low range more frequently.

ground speed (3-7 MPH) See page 102.

Insufficient warm-up at

low ambient tempera-

tures

Warm the engine at least 5 minutes. With the transmission

in neutral, advance the throttle to about 1/8 throttle in

short bursts, 5 to 7 times. The belt will become more flex-

ible and prevent belt burning.

Slow/easy clutch engage- Use the throttle quickly and effectively.

ment

Towing/pushing at low

RPM/low ground speed

Use low range only.

Utility use/plowing

Use low range only.

Stuck in mud or snow

Shift the transmission to low range and carefully use fast,

aggressive throttle application to engage clutch.

WARNING! Excessive throttle may cause loss of control

and vehicle overturn.

Climbing over large

objects from a stopped

position

Shift the transmission to low range and carefully use fast,

brief, aggressive throttle application to engage clutch.

WARNING! Excessive throttle may cause loss of control

and vehicle overturn.

Belt slippage from water Dry out the PVT. See page 102. Inspect clutch seals for

or snow ingestion into the damage if repeated leaking occurs.

PVT system

Clutch malfunction

See your Polaris dealer.

Poor engine performance Check for fouled plugs or foreign material in gas tank or

fuel lines. See your dealer.

Slippage from failure to

warm up belt

Always warm up the belt by operating below 30 mph for

one mile (5 miles or more when temperature is below

freezing).

Wrong or missing belt

Improper break-in

Install the recommended belt.

Always break in a new belt and/or clutch. See page 47.

118

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TROUBLESHOOTING

Engine Doesn't Turn Over

Possible Cause

Solution

Low battery voltage

Recharge the battery to 12.8 VDC

Check all connections and tighten

Loose battery connections

Loose solenoid connections

Engine Turns Over, Fails to Start

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three

times for 5 seconds each, then start

Clogged fuel filter

Replace the filter

Water is present in fuel

Old or non-recommended fuel

Fouled or defective spark plugs

No spark to spark plug

Water or fuel in crankcase

Low battery voltage

Drain the fuel system and refuel

Replace with fresh recommended fuel

Inspect plugs and replace if necessary

Inspect plugs, verify stop switch is on

Immediately see your Polaris dealer

Recharge the battery to 12.8 VDC

See your dealer

Mechanical failure

Engine Backfires

Possible Cause

Solution

Weak spark from spark plug

Incorrect spark plug gap or heat range

Old or non-recommended fuel

Incorrectly installed spark plug wires

Incorrect ignition timing

Inspect, clean and/or replace spark plugs

Set gap to specs or replace plugs

Replace with fresh recommended fuel

See your dealer

Mechanical failure

See your dealer

Loose ignition connections

Water present in fuel

Check all connections and tighten

Replace with fresh recommended fuel

119

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TROUBLESHOOTING

Engine Pings or Knocks

Possible Cause

Solution

Poor quality or low octane fuel

Incorrect ignition timing

Replace with recommended fuel

See your dealer

Incorrect spark plug gap or heat range

Set gap to specs or replace plugs

Engine Runs Irregularly, Stalls or Misfires

Possible Cause

Solution

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Water present in fuel

Inspect, clean and/or replace spark plugs

See your dealer

Set gap to specs or replace plugs

Check all connections and tighten

Replace with new fuel

Low battery voltage

Recharge battery to 12.8 VDC

Inspect and replace

Kinked or plugged fuel tank vent line

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

See your dealer

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

See your dealer

Possible Lean Fuel Cause

Solution

Low or contaminated fuel

Kinked or plugged fuel tank vent line

Low octane fuel

Add or change fuel, clean the fuel system

Inspect and replace

Replace with recommended fuel

Replace filter

Clogged fuel filter

Incorrect fuel

Replace with recommended fuel

Possible Rich Fuel Cause

Solution

Fuel is very high octane

Replace with lower octane fuel

Stopping/starting without adequate

warm-up

Allow engine to warm up before operat-

ing and/or stopping

Incorrect fuel

Replace with recommended fuel

Inspect and clean or replace

Clogged air filter

120

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TROUBLESHOOTING

Engine Stops or Loses Power

Possible Cause

Solution

Out of fuel

Refuel, cycle key to ON position three

times for 5 seconds each, then start

Kinked or plugged fuel vent line

Water is present in fuel

Inspect and replace

Replace with new fuel

Fouled or defective spark plugs

Worn or defective spark plug wires

Incorrect spark plug gap or heat range

Loose ignition connections

Low battery voltage

Inspect, clean and/or replace spark plug

See your dealer

Set gap to specs or replace plug

Check all connections and tighten

Recharge the battery to 12.8 VDC

Replace with fresh recommended fuel

Inspect and clean or replace

See your dealer

Incorrect fuel

Clogged air filter

Reverse speed limiter malfunction

Electronic throttle control malfunction

Other mechanical failure

Overheated engine

See your dealer

Clean radiator screen and core, clean

engine exterior, see your dealer

Engine Overheating

Possible Cause

Solution

Debris lodged in screen

Remove and clean the screen. Pull on the

top portion of the screen, then remove the

lower portion.

Plugged Radiator

Use a garden hose to flush any debris

from the radiator fins. NOTE: High pres-

sure washers can deform the radiator fins

and reduce cooling efficiency.

121

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SPECIFICATIONS

Sportsman Big Boss 6X6 800 EFI

Maximum Weight Capacity

1115 lbs. (507 kg) (includes operator, cargo,

accessories)

Fuel Capacity

4.1 gal. (15.5 l)

2 qts. (1.9 l)

Engine Oil Capacity

Coolant Capacity

3.6 qts. (3.4 l)

Demand Drive Fluid Capacity

Rear Gearcase Oil Capacity

Mid Gearcase Oil Capacity

Transmission Oil Capacity

Front Rack/Storage Box Capacity

Cargo Box Capacity

Receiver Hitch Tongue Capacity

Hitch Towing Rating

Unbraked Trailer Towing Capacity*

Overall Length

9.3 oz. (275 ml)

5 oz. (150 ml)

17 oz. (500 ml)

15 oz. (450 ml)

100 lbs. (45 kg)

800 lbs. (363 kg)

150 lbs. (68 kg)

1500 lbs. (680.4 kg)

2127 lbs. (965 kg)

112 in. (284 cm)

48 in. (122 cm)

79.5 in. (202 cm)

10.5 in. (27 cm)

1060 lbs. (481 kg)

152 in. (386 cm) unloaded

EH076OLE020

760 cc

Overall Width

Overall Height

Wheelbase

Ground Clearance

Dry Weight

Minimum Turning Radius

Engine

Displacement

Bore x Stroke

80 x 76

Alternator Output

500 Watts @ 3000 rpm

10:1

Compression Ratio

Starting System

Electric

Fuel System

Electronic Fuel Injection

ECU

Ignition System

Ignition Timing

8 BTDC @ 2000 RPM

RC7YC / .035 in. (0.9 mm)

Pressurized Wet Sump

Spark Plug / Gap

Lubrication System

Driving System Type

Automatic PVT (Polaris Variable Transmis-

sion)

Front Suspension

Rear Suspension

MacPherson strut with 8.2" (21 cm) travel

Progressive rate with 6.1" (15.5 cm) travel

* Based on EU Directive 76/432/EC

122

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SPECIFICATIONS

Sportsman Big Boss 6X6 800 EFI

Transmission

Automatic PVT with E-Z Shift H/L/N/R/P

7.49:1

Gear Reduction, Low

Gear Reduction, Reverse

Gear Reduction, High

Drive Ratio, Front

Drive Ratio, Final

Tires/Pressure, Front

Tires/Pressure, Center

Tires/Pressure, Rear

Brakes, Front

5.11:1

3.05:1

3.82:1

3.10:1

25x8-12 / 7 psi (48.3 kPa)

25x11-12 / 10 psi (68.9 kPa)

Hydraulic Disc

Brakes, Rear

Hydraulic Disc

Brakes, Auxiliary

Brake, Parking

Hydraulic Disc

Hydraulic lock, all wheel

Headlight

1 Single Beam on Headlight Pod (50 watt)

2 Single Beam on Bumper (37.5 watt)

Taillights

8.26 watts

26.9 watts

LCD

Brake Light

Instrument Cluster

Clutching

Altitude

Shift

Drive Clutch

Spring

Driven

Clutch

Spring

Helix*

EBS

Weight

Meters

(Feet)

0-1800

(0-6000)

21-74

Red/White

Red

PN 5632117 PN 7043349 PN 3234452 PN 3234604

1800-3700

(6000-12000)

21-70

Red/White

Red

EBS

PN 5632127 PN 7043349 PN 3234452 PN 3234604

*EBS models require no helix/spring adjustment

123

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POLARIS PRODUCTS

Part

Description

Number

Engine Lubricant

Fogging Oil (12 oz. Aerosol)

2870791

2876244

2876245

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (qt.)

PS-4 PLUS Performance Synthetic 2W-50 4-Cycle Oil (gal.)

Gearcase / Transmission Lubricants

Premium AGL Synthetic Gearcase Lubricant (qt./.95 l)

Premium AGL Synthetic Gearcase Lube (gal./3.8 l)

Active Descent Control (ADC) Fluid

2873602

2873603

2876144

2871653

2872276

2870465

2876251

Premium ATV Angle Drive Fluid (8 oz./237 ml)

Premium ATV Angle Drive Fluid (2.5 gal./9.5 l)

Pump for Gallon (3.8 l) Jug

Demand Drive LT Premium Fluid (8 oz./237 ml)

Coolant

2871323

2871534

60/40 Coolant (gal./3.8 l)

60/40 Coolant (qt./.95 l)

Grease / Specialized Lubricants

2871312

2871322

2871423

2871460

2871515

2871551

2871329

Grease Gun Kit, Premium All Season

Premium All Season Grease (3 oz./89 ml cartridge)

Premium All Season Grease (14 oz./414 ml cartridge)

Starter Drive Grease

Premium U-Joint Lube (3 oz./89 ml cartridge)

Premium U-Joint Lube (14 oz./414 ml cartridge)

Dielectric Grease (Nyogel^TM

Additives / Miscellaneous

Carbon Clean Plus

)

2871326

2870652

2872189

2871956

2859044

Fuel Stabilizer

DOT 4 Brake Fluid

Loctite^TM565 Thread Sealant

Polaris Battery Tender^TMCharger

124

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WARRANTY

LIMITED WARRANTY

Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, gives a SIX MONTH LIM-

ITED WARRANTY on all components of the Polaris Light Utility Vehicle against

defects in material or workmanship. Polaris also gives a one year limited warranty on

the final drive chain for failure due to defects. This warranty covers the parts and labor

charges for repair or replacement of defective parts which are covered by this warranty.

This warranty begins on the date of purchase. This warranty is transferable to another

consumer during the warranty period through a Polaris dealer.

REGISTRATION

At the time of sale, the Warranty Registration Form must be completed by your dealer

and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will

record the registration for warranty. No verification of registration will be sent to the

purchaser as the copy of the Warranty Registration Form will be the warranty entitle-

ment. If you have not signed the original registration and received the customer copy,

please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE

ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLARIS.

Initial dealer preparation and set-up of your vehicle is very important in ensuring trou-

ble-free operation. Purchasing a machine in the crate or without proper dealer set-up will

void your warranty coverage.

125

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WARRANTY

WARRANTY COVERAGE AND EXCLUSIONS:

LIMITATIONS OF WARRANTIES AND REMEDIES

The Polaris limited warranty excludes any failures that are not caused by a defect in

material or workmanship. This warranty does not cover accidental damage, normal wear

and tear, abuse or improper handling. This warranty also does not cover any vehicle that

has been altered structurally, neglected, improperly maintained, used for racing, or used

for purposes other than for which it was manufactured, or for any damages which occur

during trailer transit or as a result of unauthorized service or the use of unauthorized

parts. In addition, this warranty does not cover physical damage to paint or finish, stress

cracks, tearing or puncturing of upholstery material, corrosion, or defects in parts, com-

ponents or the vehicle due to fire, explosions or any other cause beyond Polaris' control.

This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that

are not compatible with the vehicle. The exclusive remedy for breach of this warranty

shall be, at Polaris' exclusive option, repair or replacement of any defective materials, or

components or products. THE REMEDIES SET FORTH IN THIS WARRANTY ARE

THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS

WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR

INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIP-

TION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR

ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.

Some states do not permit the exclusion or limitation of incidental or consequential

damages or implied warranties, so the above limitations or exclusions may not apply to

you if inconsistent with controlling state law.

126

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WARRANTY

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE SIX

MONTH WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS

WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limi-

tations on how long an implied warranty lasts, so the above limitation may not apply to

you if inconsistent with controlling state law.

HOW TO OBTAIN WARRANTY SERVICE

If your vehicle requires warranty service, you must take it to a Polaris Servicing Dealer.

When requesting warranty service you must present your copy of the Warranty Registra-

tion form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE

DEALER IS YOUR RESPONSIBILITY). Polaris suggests that you use your original

selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty

service.

Please work with your dealer to resolve any warranty issues. Should your dealer require

any additional assistance they will contact the appropriate person at Polaris.

This warranty gives you specific legal rights, and you may also have other rights which

vary from state to state.

If any of the above terms are void because of state or federal law, all other warranty

terms will remain in effect.

Engine Oil

1. Mixing oil brands or using non-recommended oil may cause engine damage. We rec-

ommend the use of Polaris engine oil.

2. Damage resulting from the use of non-recommended lubricants may not be covered

by warranty.

SPARK ARRESTOR

Polaris warrants that the spark arrestor in this vehicle will meet the efficiency require-

ments of 43 CFR 8343.1(c) for at least 1000 hours when subjected to normal use and

when maintenance and installation are in accordance with Polaris recommendations.

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WARRANTY

Exported Vehicles

EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-

RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD

OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-

TION.

This policy does not apply to vehicles that have received authorization for export from

Polaris Industries. Dealers may not give authorization for export. You should consult an

authorized dealer to determine this vehicle's warranty or service bulletin coverage if you

have any questions.

This policy does not apply to vehicles registered to government officials or military per-

sonnel on assignment outside the country of the selling dealer's authorized location.

This policy does not apply to Safety Recalls.

How to Get Service

In the Country where your vehicle was purchased:

Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you

move or are traveling within the country where your vehicle was purchased, Warranty or

Service Bulletin repairs may be requested from any authorized Polaris dealer who sells

the same line as your vehicle.

Outside the Country where your vehicle was purchased:

If you are traveling temporarily outside the country where your vehicle was purchased,

you should take your vehicle to an authorized Polaris dealer. You must show the dealer

photo identification from the country of the selling dealer's authorized location as proof

of residence. Upon residence verification, the servicing dealer will be authorized to per-

form the warranty repair.

If You Move:

If you move to another country, be sure to contact Polaris Customer Assistance and the

customs department of the destination country before you move. Vehicles importation

rules vary considerably from country to country. You may be required to present docu-

mentation of your move to Polaris Industries in order to continue your warranty cover-

age. You may also be required to obtain documentation from Polaris Industries in order

to register your vehicle in your new country.

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WARRANTY

Exported Vehicles

How to Get Service

If Purchased From A Private Party:

If you purchase a Polaris product from a private citizen outside of the country in which

the vehicle was originally purchased, all warranty coverage will be denied.

Notice

If your vehicle is registered outside of the country where it was purchased, and you have

not followed the procedure set out above, your vehicle will no longer be eligible for war-

ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-

cials or military personnel on assignment outside of the country where the vehicle was

purchased will continue to be covered by the basic warranty.)

For questions call Polaris Customer Assistance:

United States: 1-888-704-5290

Canada: 1-204-925-7100

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WARRANTY

U.S.A. EPA Emissions Limited Warranty

This All Terrain Vehicle (ATV) or Off Road Utility Vehicle (ORUV) emissions limited

warranty is in addition to the Polaris standard limited warranty for this vehicle.

Polaris warrants that this vehicle is; (1) designed, built, and equipped to conform at the

time of initial sale with the requirements of 40 CFR 1051 and, (2) free from defects in

materials and workmanship that may keep it from meeting these requirements.

The emissions warranty period for this vehicle begins on the date the vehicle is deliv-

ered to the original retail purchaser and ends 30 months (2.5 years) after that date, after

5000 km (3100 miles), or after 500 hours of operation, whichever comes first.

This emission-related warranty covers components whose failure would increase an

engine's emissions, including electronic controls, fuel injection, exhaust-gas recircula-

tion, aftertreatment, or any other system utilized in this vehicle to control emissions.

Replacing or repairing other components not covered by this emissions warranty or the

standard warranty is the responsibility of the owner; including the parts, labor and other

costs associated with recommended maintenance.

The exclusive remedy for breach of this limited warranty shall be, at the exclusive

option of Polaris, repair or replacement of any defective materials, components or prod-

ucts. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE

ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WAR-

RANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCI-

DENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY

DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED WAR-

RANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR

OTHERWISE.

ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY

IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PAR-

TICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY

PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS WARRAN-

TIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations on

how long an implied warranty lasts, so the above limitation may not apply if it is incon-

sistent with the controlling state law.

This limited warranty excludes failures not caused by a defect in material or workman-

ship.This limited warranty does not cover damage due to accidents, abuse or improper

handling, maintenance or use. This limited warranty also does not cover any engine that

has been structurally altered, or any engine that has been used in racing competition.

This limited warranty also does not cover physical damage, corrosion or defects caused

by fire, explosions or other similar causes beyond the control of Polaris.

If you have any questions regarding your warranty rights and responsibilities, you

should contact the Polaris Warranty Department at 1-888-704-5290.

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MAINTENANCE LOG

Present this section of your manual to your dealer each time your vehicle is serviced.

This will provide you and future owners with an accurate log of maintenance and ser-

vices performed.

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

132

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MAINTENANCE LOG

DATE

MILES (KM)

OR HOURS

TECHNICIAN

SERVICE PERFORMED / COMMENTS

133

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