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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.
A card containing important ATV safety information should be
attached to the owner's manual on the next page. If you cannot
locate this card, or if it has been removed, please call 1-800-342-
3764 for assistance.
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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!
1
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POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-
tries Inc.
Copyright 2008 Polaris Sales Inc. All information contained within this publication is
based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor 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 500/800 X2 Owner’s Manual
P/N 9921845
2
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Features and Controls . . . . . . . . . . . . . . . . . . . 28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Emission Control Systems . . . . . . . . . . . . . . . 74
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 129
Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 133
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 134
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 144
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
3
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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.
4
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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. A Polaris ATV is not a toy and can be
hazardous to operate. This vehicle handles differently than other vehicles, such
as motorcycles and cars. A collision or rollover can occur quickly, even during
routine maneuvers like turning, or driving on hills or over obstacles, if you fail to
take proper precautions.
• Read this owner’s manual. Understand all safety warnings, precautions and
operating procedures before operating a Polaris ATV. Keep this manual with
the ATV.
• Never operate an ATV without proper instruction. Take a training course.
Purchasers of a new Polaris ATV and their eligible family members are
entitled to take the ATV RiderCoursesm. Contact ATV Enrollment Express at
(800) 887-2887 or visit www.atvsafety.org for information on enrollment in the
ATV RiderCoursesm.
• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age.
• Never permit a guest to operate the ATV unless the guest has read this
manual and all product labels and has completed a certified safety training
course.
5
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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.
500
VIN
Engine Serial Number
####
Key Number
800
Vehicle Model Number: ___________________________________________________
Frame VIN: ____________________________________________________________
Engine Serial Number: ___________________________________________________
Key Number: ___________________________________________________________
6
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SAFETY
Safety Training
ATV safety training is a top priority for Polaris. When you purchased
your new ATV, your dealer instructed you on the authorized ATV
RiderCoursesm available to you and your eligible family members. This
training is included in the purchase price of your ATV. Polaris strongly
encourages you and your eligible family members who will be riding
the ATV to take the ATV RiderCoursesm. You were also provided with
printed materials that explain safe operating procedures. You should
review this information on a regular basis.
If you purchased a used Polaris ATV, you can take the ATV
RiderCoursesm by calling ATV Enrollment Express at (800) 887-2887 or
by visiting www.atvsafety.org. Purchasers of a used Polaris ATV will be
charged for this training.
A Polaris ATV is an off-road vehicle. Familiarize yourself with all laws
and regulations concerning the operation of this vehicle in your area.
We strongly advise you to strictly follow the recommended maintenance
program outlined in your owner's manual. This preventive maintenance
program is designed to ensure that all critical components on your
vehicle are thoroughly inspected at specific intervals.
FOR MORE INFORMATION ABOUT ATV SAFETY, call the
Consumer 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.
7
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SAFETY
Safe Riding Gear
Always wear appropriate clothing when riding an ATV. Wear protective
clothing for comfort and to reduce the chance of injury.
Helmet
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. A passenger (on approved models) should wear a hel-
met that includes a rigid chin guard.
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
4
E
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
8
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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 ATV
any equipment that may increase the speed or power of the vehicle, or
make any other modifications to the vehicle for these purposes.
The warranty on your Polaris ATV is terminated if any equipment has
been added to the vehicle, or if any modifications have been made to the
vehicle, that increase its speed or power.
The addition of certain accessories, including (but not limited to) 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.
9
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SAFETY
Safety Warnings
WARNING
Failure to operate the ATV 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 ATV without proper instruction
increases the risk of an accident. The operator
must understand how to operate the ATV properly
in different situations and on different types of
terrain.
Beginning and inexperienced operators should
complete the recommended safety training before
operating this vehicle. See page 7.
Never permit a guest to operate the ATV unless the
guest has read this manual and all product labels
and has completed a certified safety training
course.
Age Restrictions
This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone
under 16 years of age. Never allow anyone under 12 years of age to ride as a
passenger on this 2-up ATV.
Even though a child may be within the recommended age group for operating
some ATVs, he/she may not have the skills, abilities, or judgment needed to
operate or ride on this ATV safely and could be susceptible to accident or injury.
10
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SAFETY
Safety Warnings
Handling Gasoline
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel with the engine stopped, and outdoors or in a well ventilated
area.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• Do not overfill the tank. Do not fill the tank neck.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
Exposure to Exhaust
Engine exhaust fumes are poisonous and can cause loss of consciousness or
death in a short time. Never start the engine or let it run in an enclosed area.
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
Failure to Inspect Before Operating
Failure to inspect and verify that the ATV is in safe
operating condition before operating increases the
risk of an accident.
Always inspect the ATV before each use to make
sure it's in safe operating condition.
Always follow all inspection and maintenance
procedures and schedules described in the
owner's manual.
11
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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).
Carrying a Passenger
Do not carry a passenger until you have at
least two hours of driving experience with this vehicle.
Carrying More Than One
Passenger
Carrying more than one passenger greatly
reduces the operator's ability to balance and
control the ATV, which may result in an
accident or overturn.
Never carry more than one passenger on this
2-up ATV.
Using Alcohol or Drugs
Operating the ATV after consuming alcohol or
drugs could adversely affect operator
judgment, reaction time, balance and
perception.
Never consume alcohol or drugs before or
while operating an ATV.
12
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SAFETY
Safety Warnings
Carrying a Passenger in the
Cargo Box
A passenger riding in the cargo box could fall
from the vehicle unexpectedly or may contact
moving components, both of which can result in
severe injury or death. Never allow a passenger
to ride in the cargo box.
Operating on Pavement
Operating an ATV on paved surfaces
(including sidewalks, paths, parking lots and
driveways) may adversely affect the
handling of the ATV and could result in loss
of control and accident or overturn.
Avoid operating the ATV on pavement. ATV
tires are designed for off-road use. If it's
unavoidable, travel slowly and avoid sudden
turns or stops.
Operating on Public Roads
Operating this ATV on public streets, roads
or highways could result in a collision with
another vehicle.
Never operate the ATV on any public street,
road or highway, including dirt and gravel
roads. In many states it's unlawful to
operate ATVs on public streets, roads and
highways.
Operating at Excessive
Speeds
Operating the ATV at excessive
speeds increases the operator's risk
of losing control.
Never operate at excessive speeds.
Travel at speeds appropriate for
your skills, your passenger's skills,
and operating conditions.
13
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SAFETY
Safety Warnings
Physical Control of the ATV
Removing even one hand or foot can reduce
ability to control the vehicle or could cause loss
of balance and ejection from the ATV.
If a person's feet are not firmly planted on the
footrests, they could come into contact with the
wheels or other moving parts and lead to
accident or injury.
Always keep both hands on the handlebars
and both feet on the footrests of the ATV during
operation. A passenger should always be
seated in the passenger seat with both feet on
the footrests and both hands on the passenger grab handles at all times. The
passenger should never hold on to the operator.
Turning Improperly
Turning improperly could cause loss of
traction, loss of control, accident or
overturn.
Always follow proper procedures for
turning as described in the owner's
manual.
Practice turning at slow speeds before
attempting to turn at faster speeds.
Never turn at excessive speed.
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.
14
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SAFETY
Safety Warnings
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 61.
Never operate with the differential unlocked (
)
while operating on a hill or other irregular terrain.
Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See pages 29 and
39.
Descending Hills Improperly
Improperly descending a hill could cause loss of
control or overturn.
Always follow proper procedures for traveling
down hills as described in the owner's manual.
See page 63.
Never operate with the differential unlocked (
)
while operating on a hill or other irregular terrain.
Always move the 4X4 switch to ADC 4X4 before
ascending or descending a hill. See pages 29
and 39.
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 62.
Never attempt to turn the ATV around on any
hill until you've mastered the turning technique
(on level ground) as described in the owner's
manual. See page 64.
15
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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
before ascending or descending a hill. See
page 39.
If all forward speed is lost:
• Lean forward to keep body weight uphill. A
passenger should also lean uphill.
• Apply the single lever brakes.
• Lock the parking brake when fully stopped.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 64.
If the ATV begins rolling backwards:
• Keep operator and passenger body weight uphill.
• Never apply engine power.
• Never apply the rear brake while rolling backwards.
• Apply the single-lever brake gradually.
• When fully stopped, apply the foot brake as well, and then lock the parking
brake.
• Dismount on the uphill side of the vehicle, or on the left if the vehicle is
pointing straight uphill. Have a passenger dismount first, then the operator
may dismount.
• Turn the ATV around and remount, following the procedure described in the
owner's manual. See page 64.
Operating on Steep Hills
Operating on excessively steep hills could
cause an overturn.
Never operate on hills too steep for the ATV or
for your abilities. Never operate the ATV on
hills steeper than 15 degrees.
>15°
16
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SAFETY
Safety Warnings
Operating on Slippery Terrain
Failure to use extra caution when operating
on excessively rough, slippery or loose terrain
could cause loss of traction, loss of control,
accident or overturn.
Do not operate on excessively rough, slippery
or loose terrain until you've learned and
practiced the skills necessary to control the
ATV on such 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.
Operating Improperly in
Reverse
Improperly operating in reverse could result
in a collision with an obstacle or person.
Always follow proper operating procedures
as outlined in this manual. See page 68.
Before shifting into reverse gear, always
check for obstacles or people behind the ATV.
When it's safe to proceed, back slowly.
17
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SAFETY
Safety Warnings
Improper Tire Maintenance
Operating this ATV with improper tires or
with improper or uneven tire pressure could
cause loss of control or accident.
Always use the size and type of tires
specified for your ATV.
Always maintain proper tire pressure as
described in the owner's manual and on
safety labels.
Operating Over Obstacles
Improperly operating over obstacles could
cause loss of control or 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 67.
Skidding or Sliding
Skidding or sliding can cause loss of control
or overturn (if tires regain traction
unexpectedly).
On slippery surfaces such as ice or loose
gravel, travel slowly and use extra caution
to reduce the chance of skidding or sliding.
Do not operate on excessively slippery
surfaces.
18
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SAFETY
Safety Warnings
Operating Through Deep Water
Operating the ATV through deep or fast-
flowing water could cause the tires to float,
causing loss of control or overturn.
Avoid operating the ATV through deep or
fast-flowing water. If it's unavoidable to
enter water that exceeds the
recommended maximum depth (see page
66):
• Travel slowly.
• Balance your weight carefully.
• Avoid sudden movements.
• Maintain a slow and steady forward motion. Do not make sudden turns or
stops, and do not make sudden throttle changes.
Wet brakes may have reduced stopping ability. After leaving water, test the
brakes. Apply them lightly several times while driving. The friction will help dry
out the pads.
Improper Cargo Loading
Overloading the ATV or carrying/towing
cargo improperly may cause changes in
handling, which could cause loss of control
or an accident.
• Never exceed the stated load capacity for
this ATV.
• Cargo should be properly distributed and
securely attached.
• Reduce speed when carrying cargo or
pulling a trailer. Allow a greater distance
for braking.
• Always follow the instructions in the owner's manual for carrying cargo or
pulling a trailer.
• Always follow the instructions in the owner's manual for operating with a
passenger. See page 58.
19
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SAFETY
Safety Warnings
Operating on Frozen Bodies of
Water
Operating on frozen bodies of water may
result in serious injury or death if the ATV
and/or riders fall through the ice.
Never operate the ATV on a frozen body of
water.
Poor Visibility
Operating the ATV in darkness or inclement
weather could result in a collision or
accident, especially if operating on a road or
street. This ATV is not equipped with
highway-approved lights. Operate this
vehicle off-road only. Use caution and drive
at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness.
Clean headlights frequently and replace
burned out headlamps promptly.
20
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SAFETY
Safety Warnings
Operating a Damaged ATV
Operating a damaged ATV 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. Never secure a
passenger to the vehicle or to the operator with a belt, rope or similar device.
Hot Exhaust Systems
Exhaust system components are very hot during and after use of the vehicle.
Hot components can cause burns and fire. Do not touch hot exhaust system
components. Always keep combustible materials away from the exhaust
system. Use caution when traveling through tall grass, especially dry grass.
Unauthorized Use of the ATV
Leaving the keys in the ignition can lead to unauthorized use of the vehicle,
which could result in an accident or overturn. Always remove the ignition key
when the vehicle is not in use.
21
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SAFETY
Safety Labels and Locations
Warning labels have been placed on the vehicle for your protection.
Read and follow the instructions on each label carefully. If any of the
labels shown in this manual differ from the labels on your vehicle,
always read and follow the instructions of the labels on the vehicle.
If an informational or graphic label becomes illegible or comes off, 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.
Age 16 Warning
WARNING
Age 16 Warning
Operating this ATV if you are under the
age of 16 increases the chances of
severe injury or death to both operator
and passenger.
NEVER operate this vehicle if you are
+
+
under age 16.
7175375
General Warning
Discretionary Warning
22
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SAFETY
Safety Labels and Locations
General Warning/Discretionary Warning
WARNING
Improper ATV use can result in SEVERE INJURY or DEATH
ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR FOR
DRIVER AND PASSENGER
NEVER USE ON PUBLIC ROADS
NEVER CARRY MORE THAN 1 PASSENGER
NEVER USE WITH DRUGS OR ALCOHOL
NEVER operate:
• without proper ATV training or instruction
• at speeds too fast for your skills or the conditions
• on public roads - a collision can occur with another vehicle
• with a passenger unless passenger seat is securely in place
THE OPERATOR MUST ALWAYS:
• use proper riding techniques to avoid overturns on hills and rough terrain and
in turns
• avoid paved surfaces - pavement may seriously affect handling and control
• reduce speed and use extra caution at all times when carrying a passenger -
dismount passenger when conditions require
• make sure passenger reads and understands this label and passenger safety
label
LOCATE AND READ OPERATOR’S MANUAL.
FOLLOW ALL INSTRUCTIONS AND WARNINGS.
WARNING
• Never operate this ATV on HILLS steeper than 15 degrees
15°. To
prevent overturn on hilly terrain, use throttle and brakes gradually.
• REVERSE operation can be dangerous even at low speeds. Steering
becomes difficult. To prevent loss of control, avoid sudden braking or sharp
turns.
7175377
23
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SAFETY
Safety Labels and Locations
Passenger Safety Warning
WARNING
PASSENGER SAFETY
To reduce the risk of SEVERE INJURY or
DEATH
NEVER CARRY MORE THAN ONE
PASSENGER
+
NEVER RIDE AFTER USING DRUGS
OR ALCOHOL
NEVER carry a passenger too small to
firmly plant feet on footrests and securely
grasp hand holds.
Passenger Safety
Warning
THE PASSENGER MUST ALWAYS:
• use an approved helmet and
protective gear
• securely grasp hand holds and plant feet firmly on footrests while seated in
the passenger seat
• tell operator to slow down or stop if uncomfortable - get off and walk if
conditions require
7175379
24
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SAFETY
Safety Labels and Locations
Tire Pressure/Load Warning
WARNING
Improper tire pressure or overloading
can cause loss of control.
Tire Pressure/Load
Warning
Loss of control can result in severe
injury or death.
• Cold tire pressure:
Front: 5.0 psi (34.5 kPa)
Rear: 5.0 psi (34.5 kPa)
+
• Maximum weight capacity: 705 lbs.
(320 kg)
7175441
25
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SAFETY
Safety Labels and Locations
Box
Warning
Rack
Warning
+
+
+
Clutch Cover
Warning
Rack Warning, Front
WARNING
DO NOT TOW FROM RACK OR BUMPER. Vehicle damage or tipover may
result causing severe injury or death. Tow only from tow hooks or hitch.
Maximum combined Front Rack and Container Load: 90 lbs. (41 kg)
7174201
Clutch Cover Warning
WARNING
NO STEP
• 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.
7172563
26
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SAFETY
Safety Labels and Locations
Reverse Override Warning/AWD Caution
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.
CAUTION
Do not push switch to engage 4x4 (AWD) if the rear wheels are spinning. This
may cause severe drive shaft and clutch damage.
7175512
Box Warning
WARNING
Remove flammable material
containers from box before filling.
WARNING
Passengers can be thrown off. This
can cause serious injury or death.
Never carry passengers in cargo box.
Maximum Box Load - 400 lbs. (181 kg)
7173890
27
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FEATURES AND CONTROLS
Switches
Worklight
Differential
Switch
Headlight
Switch
Switch
(if equipped)
4X4
Switch
Mode/Reverse
Override
Engine
Stop Switch
Main Key Switch
Switch
Mode/Reverse Override Switch
This vehicle is equipped with a reverse speed limiter system.To gain
additional wheel speed while backing, depress the override switch.
WARNING! Activating the override switch while the throttle is open can cause
loss of control, which may result in serious injury or death. Always release the
throttle before activating the override switch.
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 42.
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 55.
4X4 Switch
Use the 4X4 switch to engage ADC 4X4, 4X4 or 2X4. See page 39.
28
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FEATURES AND CONTROLS
Switches
Differential Switch
Use the differential switch to lock and unlock the rear differential.
Locked Differential: Operate the vehicle with the switch in
the locked position in most conditions.
Unlocked Differential: When the differential is unlocked, the
inside wheel will rotate independently from the outside wheel
during turns. Operate with an unlocked differential only as
needed to protect smooth, level surfaces from tire damage.
Otherwise, move the switch to the locked position. This feature
will function only if the vehicle is in 2X4 mode.
WARNING! Operating with the differential unlocked ( ) when on sloped,
uneven, or loose terrain could cause loss of control and result in serious injury or
death. One rear wheel may slip and lose traction or may lift up and grab when it
touches the ground again.
DO NOT operate with the differential unlocked ( ) when climbing or
descending hills, when sidehilling, or when operating on uneven, loose, or
slippery terrain such as sand, gravel, ice, snow, obstacles, and water crossings.
Place the differential switch in the locked position and operate in ADC 4X4 or
4X4 on these types of terrain.
Worklight Switch
Use the worklight switch (if equipped) to turn the worklight on or off.
The worklight is located at the rear of the vehicle. Turn the light on
while loading and unloading cargo in low light situations. Turn the
worklight off when driving.
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.
29
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FEATURES AND CONTROLS
Throttle Lever
WARNING
Operating an ATV with sticking or improperly operating throttle controls could
cause an accident. Never start or operate an ATV that has a sticking or
improperly operating throttle. Always contact your dealer for service before
operating the vehicle.
Failure to check or maintain proper operation of the throttle system can result in
an accident if the throttle lever sticks during operation. Always check the lever
for free movement and return before starting the engine. Also check
occasionally during operation.
Modifications to the 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 properly installed to the throttle control.
Engine speed and vehicle
movement are controlled by
pressing the throttle lever. The
throttle lever is spring loaded.
Engine speed returns to idle
when the lever is released.
This ATV 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 posi-
tion when the operator releases the throttle lever, the engine will stop,
and power to the rear wheels will cease.
30
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FEATURES AND CONTROLS
Brake Lever
WARNING
Operating the ATV with a spongy brake lever can result in loss of braking, which
could cause an accident. Never operate the ATV with a spongy-feeling brake
lever. Always contact your dealer for service before operating the vehicle.
Squeeze the brake lever toward the
handlebar to apply the front and
rear brakes. These brakes are
hydraulically activated disc type
brakes that are activated by only
one lever.
Always test brake lever travel and
master cylinder fluid level before
riding. When squeezed, the lever
should feel firm. Any sponginess
would indicate a possible fluid leak or low master cylinder fluid level,
which must be corrected before riding. Contact your dealer for proper
diagnosis and repairs.
31
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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.
Check the brake fluid in the master
Master Cylinder
cylinder before each ride.
1. Position the ATV on a level
surface.
2. Position the handlebars so the
master cylinder is level.
3. View the brake fluid level
through the indicator window
on the top of the master cylin-
Indicator
Window
der. 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.
32
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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 ATV while the parking brake is engaged could result
in an accident or fire. Always check to be sure the parking brake is disengaged
before operating.
The parking brake may relax if left on for a long period of time. Always
block the wheels to prevent rolling. Always block the wheels on the
downhill side of the ATV if leaving it parked on a hill. Another option is
to park the ATV in a sidehill position. Never depend on the parking
brake alone if the ATV is parked on a hill. Always block the wheels to
prevent rolling.
33
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FEATURES AND CONTROLS
Auxiliary Foot Brake
WARNING
Aggressively applying the auxiliary 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 auxiliary brake. Do not aggressively apply the
auxiliary brake when going forward. The rear wheels may skid and slide
sideways, causing loss of control and serious injury or death.
The auxiliary brake system is intended to be used as a backup for the
main brake system. Should the main system fail, use the auxiliary foot
brake. Since this is a rear brake only, it will not be as effective as the all-
wheel single lever system.
The auxiliary foot brake is located
on the inside of the right footrest.
Operate this brake with your right
foot.
Auxiliary Foot Brake
If the rear wheels slide while using
the auxiliary brake, reduce brake
pedal pressure to brake the rear
wheels without skidding.
Brake Fluid Level
Check the brake fluid level frequently for the auxiliary brake system.
The reservoir is located under the seat. Maintain the fluid level between
the maximum and minimum marks.
34
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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.
Whenever the ATV is left unattended, always place the transmission in
PARK and lock the parking brake.
Belt Life
To extend belt life, use low forward gear in heavy pulling situations and
when operating at less than seven miles per hour for extended periods of
time.
35
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FEATURES AND CONTROLS
Fuel Filter (500 EFI)
The in-line fuel filter is located under the rubber service cover inside the
front box. Have your dealer replace the filter after every 200 hours of
operation and any time the fuel becomes contaminated with dirt or
debris. Do not attempt to clean the fuel filter.
Fuel Tank Cap
Remove the fuel tank cap to add
fuel to the fuel tank. Use either
leaded or unleaded gasoline with
a minimum pump octane number
of 87=(R+ M/2) octane. Do not
use E-85 fuel.
Fuel
Tank
Cap
36
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FEATURES AND CONTROLS
All Wheel Drive System
The All Wheel Drive system is
controlled by the 4X4 switch.
ADC 4X4 Mode
When the switch is on ADC 4X4,
the ADC system allows engine
braking to all four wheels when
the vehicle descends a hill or
incline. Always move the 4X4
switch to ADC 4X4 before
ascending or descending a hill.
See page 39.
4X4
Switch
4X4 Mode
When the switch is on 4X4, the ATV is in 4X4, and the 4X4 indicator
light in the instrument cluster will be on.
When in 4X4, the demand drive unit will automatically engage any time
the rear wheels lose traction. When the rear wheels regain traction, the
demand drive unit will automatically disengage. There is no limit to the
length of time the vehicle may remain in 4X4.
Tip: The override switch allows activation of 4X4 in reverse if the 4X4 switch is
on. See page 28.
2X4 Mode
When the switch is on 2X4, the ATV is in two-wheel drive at all times.
37
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FEATURES AND CONTROLS
All Wheel Drive System
Engaging 4X4
The 4X4 switch may be turned on or off while the vehicle is moving.
Initially, the vehicle's electronic system will not enable 4X4 until the
engine RPM is below 3100. Once enabled, 4X4 remains enabled until
the 4X4 switch is turned off. If the switch is turned off while the demand
drive unit is moving, it will not disengage until the rear wheels regain
traction.
Engage the 4X4 switch before getting into conditions where front wheel
drive may be needed. If the rear wheels are spinning, release the throttle
before switching to 4X4.
NOTICE: Switching to 4X4 or ADC 4X4 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.
38
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FEATURES AND CONTROLS
Active Descent Control (ADC) System
The ADC system allows engine braking to all four wheels when the
vehicle descends a hill or incline. Always move the 4X4 switch to ADC
4X4 before ascending or descending a hill.
Engaging Active Descent Control
The ADC system will automatically engage when all four of the 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
39
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FEATURES AND CONTROLS
Passenger Seat
Always make sure the passenger seat lock-out is functioning properly
before operating with a passenger.
Do not operate the vehicle with the seat in the 2-up position when oper-
ating without a passenger. Always return the seat to the 1-up position for
single-rider operation.
Never carry cargo in the rear box when operating the ATV in the 2-up
mode with a passenger.
Seat Conversion
1. Make sure the cargo box dump lever is securely latched.
2. Rotate both operator backrest latches 1/4 turn to release the locks.
3. Tilt the backrest slightly forward.
4. Pull the passenger backrest upward from the bed of the cargo box.
Operator Backrest Latches
(view from front)
Locked
Unlocked
Passenger
Backrest
Dump Lever
40
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FEATURES AND CONTROLS
Passenger Seat
Seat Conversion
5. Lift the adjustment latch at the top of the passenger backrest. Raise
the backrest to the desired position. Release the latch, making sure
it locks into one of the three operating positions.
Tip: The backrest must be moved out of the lowest position before it can be
secured in the upright position. The lowest position is for seat storage only.
Do not leave the backrest in the lowest position. Always adjust the backrest
to one of the three operating positions.
6. Lower the operator
Adjustment
Backrest
backrest to create the
Latch
passenger seat. Two
retaining pins under the
seat should fit into the two
grommets on the seat base.
Passenger
7. Test the passenger seat
lock-out by attempting to
release the cargo box dump
lever. If the dump lever
releases, the seat is not
secure. Repeat the set-up
procedure. If the lock-out
is not working properly, do
not allow a passenger to
ride the vehicle. See your Polaris dealer for service.
8. To return the vehicle to single-rider
Locked
operation, reverse all steps. Always
lower the passenger backrest to the
lowest position before folding it
down into the cargo box. Turn the
operator backrest latches 1/4 turn to
secure the locks.
41
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FEATURES AND CONTROLS
Instrument Cluster
Your ATV is equipped with an instrument cluster that senses vehicle
speed from a sensor in the transmission. 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
ATV's speed to approximately 7-9 mph. Refer to page 28 for additional
information.
Speedometer
Needle
Speedometer
Rider
Information
Center
NOTICE: High water pressure may damage ATV components. Wash the ATV
by hand or with a garden hose using mild soap.
Certain products, including insect repellents and chemicals, will
damage the speedometer lens and other plastic surfaces. Do not use
alcohol to clean the instrument cluster. Do not allow insect sprays to
contact the lens. Immediately clean off any gasoline that splashes on
the instrument cluster.
42
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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 ATV to your Polaris dealer for proper diagno-
sis.
1. Gear Indicator - This
indicator displays gear
shifter position:
H = High Gear
6
3
4
5
7
8
L = Low Gear
N = Neutral
R = Reverse Gear
P = Park
2
2. 4X4 Indicator - This
indicator illuminates
when the 4X4 switch
is on either ADC 4X4
or 4X4.
9
1
3. Engine Hour Display Indicator
4. Service Interval/Diagnostic Mode Indicator
5. Low Battery and Over Voltage - This warning usually indicates
that the ATV 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 ATV if
this warning appears. Serious engine damage could result.
9. Mode Indicator
43
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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 28. The transmission
cannot be in reverse when using this feature.
Odometer Mode
The odometer records the miles traveled by the ATV.
Trip Meter Mode
The trip meter records the miles traveled by the ATV 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
45.
44
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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.
45
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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 47.
The service interval is programmed at 50 hours at the factory.
46
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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.
47
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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 49 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. Stop
the engine. Turn the key switch to the
ON position.
2. Turn the key switch off and on three
times in less than five seconds. The
word “WAIt” will appear on the screen.
3. The Check Engine icon will blink once, pause, then blink twice
(blink code 12) to begin the diagnostic sequence. The EFI module is
now searching for blink codes. If a code exists, the Check Engine
icon will flash the code.
4. Count the number of times the Check Engine icon flashes.
Example: For the two blink codes 42 and 36, the Check Engine icon will
flash 4 times, pause, then flash 2 times (code 42), then pause longer,
blink 3 times, pause, and blink 6 times (code 36).
5. A code 61 will signal the end of the sequence. If no blink codes are
found, only codes 12 and 61 will appear during the sequence.
Tip: The word “WAIt” will remain on the screen through this entire process.
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.
48
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FEATURES AND CONTROLS
Instrument Cluster
Rider Information Center
Downloading Codes
Blink
Code
Failure Description
12
22
22
22
25
31
31
36
36
37
37
41
41
42
42
44
45
46
47
47
51
51
52
52
55
55
56
56
58
58
59
59
63
63
72
73
73
74
74
61
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
Rear Differential Enable: Shorted Load/Short-to-Battery
END SEQUENCE
49
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OPERATION
WARNING
Failure to operate the ATV 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 ATV 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.
50
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OPERATION
Break-In Period
Engine and Drivetrain Break-in
1. Fill the fuel tank with gasoline. See page 36. Always exercise
extreme caution whenever handling gasoline.
2. Check the engine oil level on the dipstick. See page 80. 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 52.
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.
51
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OPERATION
Pre-Ride Checklist
Failure to inspect and verify that the ATV is in safe operating condition
before operating increases the risk of an accident. Always inspect the
ATV before each use to make sure it's in safe operating condition.
Item
Remarks
Page
Passenger seat lock-out
Brake system/lever travel
Ensure proper operation
Ensure proper operation
40
31
94
Brake fluid
Ensure proper level
32
34
79
79
-
Auxiliary brake
Front suspension
Rear suspension
Steering
Ensure proper operation
Inspect, lubricate if necessary
Inspect, lubricate if necessary
Ensure free operation
Tires
Inspect condition and pressure
Inspect, ensure fastener tightness
97
Wheels/fasteners
97
98
Frame nuts, bolts, fasteners Inspect, ensure tightness
-
Fuel and oil
Ensure proper levels
36
80
Coolant level (if applicable)
Ensure proper level
92
93
Coolant hoses (if applicable) Inspect for leaks
-
Throttle
Ensure proper operation
30
128
Indicator lights/switches
Engine stop switch
Air filter, pre-filter
Air box sediment tube
Headlamp
Ensure operation
28
28
99
-
Ensure proper operation
Inspect, clean
Drain deposits whenever visible
Check operation, apply Polaris dielec-
tric grease when lamp is replaced
29
102
Brake light/taillight
Riding gear
Check operation, apply Polaris dielec-
tric grease when lamp is replaced
105
8
Wear approved helmet, goggles, and
protective clothing
ADC Fluid
Ensure proper level
90
52
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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. Engine exhaust fumes are poisonous. Never start the engine or let it
run in an enclosed area.
4. Before operating, learn how to use the auxiliary brake for emer-
gency situations (if service brakes become inoperable).
5. Operate this vehicle off-road only. Never operate the vehicle on
pavement or on any public street, road or highway, including dirt
and gravel roads.
6. Use caution and drive at reduced speeds in conditions of reduced
visibility such as fog, rain and darkness. Clean headlights fre-
quently and replace burned out headlamps promptly.
7. Drive in a manner appropriate for your skills, your passenger’s
skills and operating conditions. Never operate at excessive speeds.
Never attempt wheelies, jumps, or other stunts. Never remove your
hands from the handlebars while operating, and always keep both
feet on the footrests.
8. Never consume alcohol or drugs before or while operating an ATV.
9. Always use the size and type of tires specified for your vehicle.
Always maintain proper tire pressure.
10. Never operate a damaged ATV. After any overturn or accident, have
a qualified service dealer inspect the entire machine for possible
damage.
11. Never operate the ATV on a frozen body of water.
12. Do not touch hot exhaust system components. Always keep com-
bustible materials away from the exhaust system.
13. Always remove the ignition key when the vehicle is not in use to
prevent unauthorized use.
53
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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.
54
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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.
Tip: Do not press the throttle while starting the engine.
5. 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.
500 EFI ONLY: The starter will automatically stop if engaged for longer than
5 seconds. Move the key to the OFF position and wait 10 seconds before
engaging the starter again.
6. If the engine does not start, return the key to the OFF position and
wait five seconds before attempting to start again. Activate the
starter for another five seconds if necessary. Repeat this procedure
until the engine starts.
NOTICE: Operating the vehicle immediately after starting could cause engine
damage. Allow the engine to warm up for several minutes before
operating the vehicle.
Cold Weather Operation
If the ATV is used year-round, check the oil level frequently. A rising oil
level could indicate the accumulation of contaminates such as water or
excess fuel in the bottom of the crankcase. Water in the bottom of the
crankcase can lead to engine damage and must be drained. Water 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.
55
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OPERATION
Driving Procedures
1. Wear protective riding gear. See page 8.
2. Perform the pre-ride inspection. See page 52.
3. Place the transmission in PARK.
4. Lock the parking brake.
5. Mount the vehicle from the left side.
6. Sit upright with both feet on the footrests and both hands on the
handlebars.
7. Start the engine and allow it to warm up.
8. Shift the transmission into gear.
9. Check your surroundings and determine your path of travel.
10. Release the parking brake.
11. Slowly depress the throttle with your right thumb and begin driving.
12. Drive slowly. Practice maneuvering and using the throttle and
brakes on level surfaces.
56
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OPERATION
Turning the Vehicle
Both rear wheels drive
equally at all times (except
when operating in 2X4 mode
with the differential
unlocked). This means that
the outside wheel must travel
a greater distance than the
inside wheel when turning,
and the inside tire must slip
traction slightly.
1. Slow down.
2. Never turn quickly when
carrying a passenger or
cargo.
3. Steer in the direction of
the turn.
4. Keep both feet on the footrests.
5. Lean your upper body to the inside of the turn while supporting your
weight on the outer footrest.This technique alters the balance of
traction between the rear wheels, allowing the turn to be made
smoothly. The same leaning technique should be used for turning in
reverse.
6. Practice making turns at slow speeds before attempting to turn at
faster speeds.
WARNING! Turning improperly can result in vehicle overturn. Never turn
abruptly or at sharp angles. Never turn at high speeds.
57
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OPERATION
Driving with a Passenger
1. Never allow anyone under 12 years of age to ride as a passenger on
this 2-up ATV. Make sure any passenger is tall enough to comfort-
ably and safely reach the grab handles and footrests.
2. Do not carry a passenger until you have at least two hours of driving
experience with this vehicle.
3. Make sure the passenger is wearing appropriate riding gear, includ-
ing an approved helmet with a rigid chin guard. See page 8.
4. Perform the pre-ride
inspection. See page 52.
5. Convert the seat for 2-up
riding. See page 40.
Always make sure the
passenger seat lock-out is
functioning properly
before carrying a
passenger.
6. Lock the parking brake.
7. Mount the vehicle from the
left side. After the operator
is seated, the passenger
should mount the vehicle
from the left side. Always
make sure the brake is
engaged to ensure the vehicle remains motionless whenever a pas-
senger mounts or dismounts.
8. Allow a passenger to ride only in the approved passenger seat.
9. Never carry more than one passenger.
10. Slow down. Control may be more difficult with a passenger on
board. Allow more time and distance for braking.
58
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OPERATION
Driving with a Passenger
11. Ride to the ability of your passenger, instead of to your own ability.
Avoid unexpected or aggressive maneuvers that could cause a pas-
senger to fall from the vehicle.
12. Do not cross a hillside with a passenger on board. See page 62.
13. A passenger should always be seated in the passenger seat with both
feet on the footrests and both hands on the passenger grab handles
at all times. The passenger should never hold on to the operator.
Never secure a passenger to the vehicle or to the operator with a
belt, rope or similar device.
14. Make sure the passenger understands the importance of "active
riding." When hill-climbing or performing maneuvers, a passenger
should shift body weight in the same manner in which the driver
shifts body weight. For example, the passenger should lean to the
inside of a turn along with the operator and should always lean
uphill when climbing and descending hills.
59
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OPERATION
Driving on Slippery Surfaces
Whenever riding on slippery surfaces such as wet trails or loose gravel,
or during freezing weather, follow these precautions:
1. Do not operate on excessively rough, slippery or loose terrain.
2. Slow down when entering slippery areas.
3. Engage 4X4 before wheels begin to lose traction.
NOTICE: Severe damage to drive train may occur if the 4X4 is engaged while
the wheels are spinning. Allow the rear wheels to stop spinning
before engaging 4X4, or engage 4X4 before wheels begin to lose
traction.
4. Maintain a high level of alertness, reading the trail and avoiding
quick, sharp turns, which can cause skids.
5. Never apply the brakes during a skid. Correct a skid by turning the
handlebars in the direction of the skid and shifting your body
weight forward.
Turn in
direction of
skid
Sideways
skid
60
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OPERATION
Driving Uphill
15° 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 before ascending or
descending a hill. See page 39.
2. Never operate with the differential unlocked ( ) while operating
on a hill or other irregular terrain. See pages 29 and 39.
3. Drive straight uphill.
4. Avoid steep hills (15° maximum).
5. Always check the terrain carefully before ascending any hill.
6. Never climb hills with excessively slippery or loose surfaces.
7. Keep both feet on the footrests.
8. Shift body weight uphill. A passenger should also shift body weight
uphill.
9. Proceed at a steady rate of speed and throttle opening. Opening the
throttle suddenly could cause the ATV to flip over backwards.
10. Never go over the top of any hill at high speed. An obstacle, a sharp
drop, or another vehicle or person could be on the other side of the
hill.
11. Remain alert and be prepared to take emergency action. This may
include quick dismounting of the vehicle.
61
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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. If operating in 2X4 mode, make sure the differential is locked.
4. Do not cross a hillside with a passenger on board. Ask the passenger
to dismount and walk across the hillside before remounting the
vehicle.
5. Lean into the hill, transferring your upper body weight toward the
hill while keeping your feet on the footrests.
6. If the vehicle begins to tip, quickly turn the front wheel downhill, if
possible, or dismount on the uphill side immediately!
62
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OPERATION
Driving Downhill
15° Maximum
When driving downhill, follow these precautions:
1. Always check the terrain carefully before descending a hill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.
3. Always descend a hill with the transmission in forward gear. Do not
descend a hill with the transmission in neutral.
4. Slow down. Never travel down a hill at high speed.
5. Drive straight downhill. Avoid traveling down a hill at an angle,
which would cause the vehicle to lean sharply to one side.
6. Shift body weight uphill. A passenger should also shift body weight
uphill.
7. Apply the brakes slightly to aid in slowing. Applying the brakes too
firmly may cause the rear wheels to lock, which could result in loss
of control.
63
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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)
64
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OPERATION
Turning Around on a Hill (K-Turn)
1. Stop and lock the parking brake while keeping body weight uphill.
2. Always move the 4X4 switch to ADC 4X4 before ascending or
descending a hill. See page 39.
3. Leave the transmission in forward and shut off the engine.
4. If a passenger is on board, ask the passenger to dismount first, then
the operator may dismount. Dismount on the uphill side of the vehi-
cle, or on the left if the vehicle is pointing straight uphill. A passen-
ger should not remount until the vehicle returns to firm, level
ground.
5. Staying uphill of the vehicle, turn the handlebars full left.
6. While holding the brake lever, release the parking brake lock and
slowly allow the vehicle to roll around to your right until it's point-
ing across the hill or slightly downward.
7. Lock the parking brake. Remount the vehicle from the uphill side,
keeping body weight uphill.
8. Start the engine with the transmission still in forward.
9. Release the parking brake and proceed slowly, controlling speed
with the brake lever, until the vehicle is on more level ground.
65
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OPERATION
Driving Through Water
Your ATV can operate
through water with a
maximum recommended
depth equal to the bottom of
the footrests. Follow these
procedures when operating
through water:
1. Determine water depths
and current before
entering water.
2. Choose a crossing where
both banks have grad-
ual 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 75. The following areas need
special attention: engine oil, transmission oil, demand drive fluid 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 108,
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.
66
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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.
5. Always have a passenger dismount before operating over an obsta-
cle that could cause a fall from the vehicle or vehicle tipover.
67
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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. Be aware
that a passenger can obstruct your view.
2. Always avoid backing downhill.
3. Back slowly.
4. Apply the brakes lightly for stopping.
5. Avoid turning at sharp angles.
6. Never open the throttle suddenly.
7. Do not use the override switch 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.
68
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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.
69
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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. Always follow these
precautions when hauling cargo:
Never carry cargo in the rear box when operating the ATV in the 2-up mode with
a passenger.
REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING
WHEN HAULING CARGO.
NEVER EXCEED THE MAXIMUM WEIGHT CAPACITY of the vehicle. When
determining the weight you are adding to the vehicle, include the weight of the
operator, passenger, accessories, loads in the rack or box and the load on the
trailer tongue. The combined weight of these items must not exceed the
maximum weight capacity.
REDUCE SPEED AND CARGO to maintain stable driving conditions when
operating over rough or hilly terrain.
WEIGHT DISTRIBUTION in the cargo bed should be as far forward and as low
as possible. Carrying a high load raises the center of gravity and creates a less
stable operating condition. Reduce load weight when cargo is high. When
handling off-centered loads that cannot be centered, secure the load and
operate with extra caution.
SECURE ALL LOADS BEFORE OPERATING. Unsecured loads may shift and
create unstable operating conditions, which could result in loss of control of the
vehicle. Always be sure that the cargo bed is lowered and latched before
moving the vehicle.
USE EXTREME CAUTION when operating with loads extending beyond the
rack or cargo bed. Stability and maneuverability may be adversely affected,
causing the machine to overturn.
BALANCE LOADS proportionally between the front rack and cargo bed, but do
not exceed the stated load capacity. Carrying a load on only the front rack or
cargo bed may cause an imbalanced condition and increases the possibility of
vehicle overturn.
USE EXTREME CAUTION when applying brakes with a loaded vehicle. Avoid
terrain or situations that may require backing downhill.
Always attach the tow load to the hitch point.
DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS. The
vehicle should never exceed 10 mph (16 kph) while towing a load on a level
surface. Vehicle speed should never exceed 5 mph (8 kph) when towing loads in
rough terrain, while cornering, or while ascending or descending a hill.
DO NOT BLOCK THE FRONT HEADLIGHT BEAM when carrying loads on the
front rack.
70
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OPERATION
Hauling Cargo
Never exceed the weight
capacities specified for your
ATV on warning labels and in
the specifications section of
this manual.
Cargo weight should be
mounted as low as possible.
When operating over rough or
hilly terrain, reduce speed and
cargo weight to maintain sta-
ble driving conditions.
1. Always load the cargo
box with the load as far
forward as possible.
2. Do not obstruct the headlight beam with cargo.
3. Use low forward gear when hauling or towing heavy cargo to
extend belt life.
4. Always operate the vehicle with extreme caution whenever hauling
or towing loads. Balance, handling, and control may be affected.
5. Slow down.
6. Make sure the cargo box dump latch is securely latched before load-
ing and operating. Unintentional dumping will result if weight is
placed in the rear of the box and the latch is not secured.
71
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OPERATION
Hauling Cargo
Towing Loads
Always attach a towed load to the hitch point. Remove the hitch from
the ATV when not towing a trailer. If towing a load, reduce rear rack
cargo weight by the amount of tongue weight.
• The combination of rear rack cargo weight and tongue weight must
not exceed the rear rack capacity.
• The total load (operator, passenger, accessories, cargo and weight on
hitch) must not exceed the maximum weight capacity of the vehicle.
NOTICE: Using an improper hitch or
Maximum
4" (10 cm)
exceeding the maximum tongue
weight capacity can result in serious
damage to the vehicle and will void
your ATV warranty. Never install a
hitch longer than 4" (10 cm). Never
install automotive accessories on
your Polaris ATV. Always install
Polaris-approved (or equivalent)
accessories designed for ATV use.
Maximum Towing Capacities
Do not exceed the following maximum capacities when towing. Avoid
towing on inclines.
500 EFI
800 EFI
Maximum Towed Load (Level Ground)
Maximum Vertical Hitch Weight
1225 lbs. (557 kg)
120 lbs. (55 kg)
1500 lbs. (680 kg)
150 lbs. (68 kg)
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OPERATION
Hauling Cargo
Dumping Cargo
1. Select a level site to dump the cargo box. Do not attempt to dump or
unload the vehicle while parked on an incline.
2. Place the transmission in PARK.
3. Lock the parking brake.
4. Dismount the vehicle.
5. Lower the tailgate.
WARNING! If cargo weight is placed toward the rear of the cargo box, the load
may dump unexpectedly and cause serious injury. When loading cargo, always
position the weight as far forward and as low as possible.
6. Pull the cargo box release lever
upward.
7. Lift the front of the cargo box and
dump the cargo.
Dump Box
8. Lower the cargo box and make
Release
sure the release latch is secured.
9. Secure the tailgate.
Latch
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 bed, damaging the
vehicle and creating hazardous driving
conditions. Never operate this vehicle with
the cargo box in the raised position.
73
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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 emissions label is located on the battery box.
Electromagnetic Interference
This spark ignition system complies with Canadian ICES-002.
This vehicle complies with the EMC requirements of European direc-
tives 97/24/EC and 2004/108/EC.
74
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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 144.
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 Q 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
E
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.)
Q
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
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
Pre-Ride
-
-
-
-
-
-
-
-
Make adjustments as
needed. See Pre-Ride
Checklist on page 52.
Front suspension
Rear suspension
Tires
Brake fluid level
Brake lever travel
Brake system
Passenger seat
lock-out
Wheels/fasteners
Frame fasteners
Engine oil level
-
-
-
-
Pre-Ride
Pre-Ride
Pre-Ride
Daily
-
-
-
-
X Air filter, pre-filter
Inspect; clean often; replace
as needed
E
X Air box sediment
-
-
-
-
Daily
Daily
Daily
Daily
-
-
-
-
Drain deposits when visible
tube
Coolant
(if applicable)
Check level daily, change
coolant every 2 years
X ADC fluid
Check level daily, add as
needed
(ADC models)
Headlight/taillight/
worklight
Check operation; apply
dielectric grease if replacing
lamps
76
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MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
X Air filter,
-
Weekly
Monthly
-
Inspect; replace as needed
E main element
X Brake pad wear
10 H
100 (160) Inspect periodically
Q
Battery
20 H
25 H
Monthly
Monthly
200 (320) Check terminals; clean; test
250 (400) Inspect level; change yearly
X Rear gearcase oil
(if equipped)
X Transmission oil
25 H
Monthly
Monthly
Monthly
250 (400) Inspect level; change yearly
250 (400) Inspect level; change yearly
250 (400) Inspect; clean if needed
X Demand drive fluid 25 H
X Engine breather
E filter (if equipped)
25 H
X General
50 H
3 M
500 (800) Lubricate all fittings, pivots,
cables, etc.
lubrication
Shift linkage
50 H
50 H
50 H
50 H
50 H
6 M
6 M
6 M
6 M
6 M
500 (800) Inspect, lubricate
500 (800) Lubricate
500 (800) Lubricate
500 (800) Lubricate
Q
Steering
X Front suspension
X Rear suspension
Q
E
Throttle Cable/
ETC Switch
500 (800) Inspect; adjust; lubricate;
replace if necessary
E Throttle Body
50 H
50 H
50 H
6 M
6 M
6 M
500 (800) Inspect duct for proper seal-
ing/air leaks
Intake Duct
Drive belt
500 (800) Inspect; adjust; replace as
needed
Cooling system
(if applicable)
1000 (1600) Inspect coolant strength
seasonally; pressure test
system yearly
X Engine oil change 100 H
X Oil filter change 100 H
6 M
6 M
1000 (1600) Perform a break-in oil change
at one month
1000 (1600) Replace with oil change
77
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MAINTENANCE
Periodic Maintenance Chart
Item
Maintenance Interval
Remarks
(whichever comes first)
Hours Calendar
Miles
(Km)
Q
E
Valve clearance
Fuel system
100 H
100 H
12 M
12 M
1000 (1600) Inspect; adjust
1000 (1600) Check for leaks at tank cap,
lines, filter, pump; replace
lines every two years
X Radiator
(if applicable)
100 H
100 H
12 M
12 M
1000 (1600) Inspect; clean external
surfaces
X Cooling hoses
1000 (1600) Inspect for leaks
(if applicable)
X Engine mounts
100 H
100 H
12 M
12 M
1000 (1600) Inspect
1000 (1600) Inspect
Exhaust muffler/
pipe
Q
E
Spark plug
100 H
100 H
12 M
12 M
1000 (1600) Inspect; replace as needed
X Wiring
1000 (1600) Inspect for wear, routing,
security; apply dielectric
grease to connectors
subjected to water, mud, etc.
Q
Clutches (drive
100 H
100 H
12 M
12 M
1000 (1600) Inspect; clean; replace worn
parts
and driven)
Q
Front wheel
bearings
1000 (1600) Inspect; replace as needed
Q
Brake fluid
200 H
200 H
24 M
24 M
2000 (3200) Change every two years
2000 (3200) Change every two years
Q
ADC fluid
(ADC models)
X Fuel filter
200 H
24 M
2000 (3200) Check for leaks around lines.
Replace every 2 years, more
often under
Q
E
extreme conditions.
Spark arrestor
300 H
36 M
3000 (4800) Clean out
Q
Toe adjustment
-
Inspect periodically; adjust
when parts are replaced
Headlight aim
-
Adjust as needed
X Perform these procedures more often for vehicles subjected to severe use.
E Emission-Related Service
Q Have an authorized Polaris dealer perform these services.
78
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MAINTENANCE
Lubrication Guide
Check and lubricate all components at the intervals outlined in the
Periodic Maintenance Chart beginning on page 75. Items not
listed in the chart should be lubricated at the General Lubrication
interval.
The a-arms and upper control arms are lubricated at the factory,
and no additional lubrication will be needed. However, if these
components are subjected to severe use, grease zerks have been
provided for additional lubrication at the user's discretion.
Item
Lube
Capacity at
Fluid Change
Inspection Procedure
Engine Oil
PS-4 PLUS
Performance
Synthetic 2W-50
2 qt. (1.9 l)
See page 80.
Brake Fluid
DOT 4 Only
---
See page 32.
Transmission Oil
Polaris AGL Syn-
thetic
Gearcase Lube
32 oz. (948 ml) See page 88.
Demand Drive
Fluid
(Front Gearcase)
Demand Drive LT
Premium Fluid
9.3 oz. (275 ml) See page 89.
ADC Fluid
Polaris ADC Fluid
---
---
See page 90.
Front Prop Shaft
Yoke
Polaris Premium
U-Joint Lube
Grease fittings (3 pumps
maximum) every 500 miles,
before long periods of stor-
age, or after pressure wash-
ing or submerging.
Front Prop Shaft Yoke
79
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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. See page 79.
Oil may need to be changed more frequently if Polaris oil is not used.
Always use 2W-50 oil. Follow the manufacturer's recommendations for
ambient temperature operation. See page 133 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.
80
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MAINTENANCE
Engine Oil
Oil Level (500 EFI)
Access the oil dipstick and fill tube
from the left side of the ATV.
Tip: A rising oil level between checks in
cool weather driving can indicate
contaminants such as gas or mois-
ture collecting in the crankcase. If
the oil level is over the full/safe
mark, change the oil immediately.
1. Position the vehicle on a level
surface.
Dipstick
2. Start the engine. Allow it to idle
for 20-30 seconds. Stop the
engine.
Safe Range
3. Remove the dipstick. Wipe it
dry with a clean cloth.
4. Reinstall the dipstick
completely.
Safe
Add Oil
5. Remove the dipstick and check
the oil level. Maintain the oil
level in the safe range. Do not
overfill.
6. Reinstall the dipstick securely.
81
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MAINTENANCE
Engine Oil
Oil Level (800 EFI)
Access the oil dipstick and fill tube
from the left side of the ATV.
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.
82
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MAINTENANCE
Engine Oil
Oil and Filter Change (500 EFI)
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 75.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to idle for two to three minutes.
3. Stop the engine.
4. Clean the area around the drain
plug.
5. Place a drain pan under the oil
tank.
Screen
Fitting
Drain
Plug
6. Remove the drain plug. Allow
the oil to drain completely.
CAUTION!Hot oil can cause burns to
skin. Do not allow hot oil to contact skin.
New Sealing Washer
7. Install a new sealing washer on
the drain plug. The sealing sur-
faces on drain plug and crank-
case should be clean and free of
burrs, nicks or scratches.
8. Reinstall the drain plug. Torque
to 14-17 ft. lbs. (19-23 Nm).
9. Disconnect the lower oil deliv-
ery hose and remove the screen
fitting from the oil tank. Clean
the fitting.
Alignment Mark
Tip: The fitting threads must be sealed with LOCTITE PST 505 or PTFE seal
tape.
10. Reinstall the screen fitting and rotate the fitting clockwise a mini-
mum of 2 1/2 turns into the tank threads. Continue to rotate the fit-
ting until the nipple of the fitting aligns with the mark on the tank.
Tip: Do not over-tighten. Maximum torque for the screen fitting is 25 ft. lbs. (34
Nm).
11. Reattach the oil line.
83
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MAINTENANCE
Engine Oil
Oil and Filter Change (500 EFI)
12. Place shop towels beneath the oil
filter. Using an oil filter wrench,
turn the filter counterclockwise to
remove it.
13. Make sure the o-ring from the old
filter is completely removed from
the engine. Using a clean dry
cloth, clean the filter sealing sur-
face on the crankcase.
14. 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.
15. 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.
16. Approximately one cup of engine oil will remain in the crankcase.
To drain, remove the drain plug on the lower right side of the crank-
case.
17. Reinstall the drain plug. The sealing surfaces on the drain plug and
crankcase should be clean and free of burrs, nicks or scratches.
18. Torque to 14 ft. lbs. (19 Nm).
19. Remove the dipstick.
20. Add two quarts (1.9 l) of recommended oil. If the sump is not
drained, add about 1 3/4 quarts (1.6 l) initially.
21. Reinstall the dipstick.
22. Place the transmission in PARK.
23. Lock the parking brake.
24. Prime the oil pump using the procedure on page 85. Then stop
the engine and inspect for leaks.
25. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
26. Dispose of used filter and oil properly.
84
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MAINTENANCE
Engine Oil
Oil and Filter Change (500 EFI)
Oil Pump Priming
This priming procedure must be
performed whenever the oil hose
connection between the oil tank and
pump inlet has been disconnected.
Tank
2"
(5 cm)
1. Clamp or pinch off the vent line
approximately 2" (5 cm) from
the oil tank, between the end of
the oil tank vent fitting and the
vent line's pressure relief slit.
Clamp
Pressure
Relief Slit
2. Start the engine. Allow it to idle
for 10-20 seconds.
3. Remove the vent line clamp. If the line is bled properly, you should
hear a rush of air, indicating that the line is properly primed and
ready for operation.
Tip: If you do not hear air, the line has not bled. Repeat the priming procedure.
85
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MAINTENANCE
Engine Oil
Oil and Filter Change (800 EFI)
Always change the oil and filter at the intervals outlined in the Periodic
Maintenance Chart beginning on page 75. Always change the oil filter
whenever changing oil.
1. Position the vehicle on a level surface.
2. Start the engine. Allow it to warm up at idle for two to three min-
utes.
3. Stop the engine.
Drain Plug Location
4. Clean the area around
the drain plug.
5. Place a drain pan
under the crankcase.
6. Remove the drain
plug. Allow the oil to
drain completely.
CAUTION!Hot oil can cause
burns to skin. Do not allow
hot oil to contact skin.
to front
7. Install a new sealing washer on the drain plug. The sealing surfaces
on drain plug and crankcase should be clean and free of burrs, nicks
or scratches.
8. Reinstall the drain plug. Torque to 20 ft. lbs. (27 Nm).
86
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MAINTENANCE
Engine Oil
Oil and Filter Change (800 EFI)
9. Place shop towels beneath the oil fil-
ter. Using an oil filter wrench (avail-
able from your Polaris dealer), turn
the filter counterclockwise to
remove it.
10. Using a clean dry cloth, clean the fil-
ter sealing surface on the crankcase.
11. Lubricate the o-ring on the new filter
with a film of fresh engine oil.
Check to make sure the o-ring is in good condition.
12. Install the new filter and rotate it clockwise by hand until the filter
gasket contacts the sealing surface, then turn it an additional 1/2
turn.
13. Remove the dipstick.
14. Add two quarts (1.9 l) of recommended oil.
15. Place the transmission in PARK.
16. Lock the parking brake.
17. Start the engine. Allow it to idle for one to two minutes.
18. Stop the engine.
19. Check for leaks.
20. Check the oil level. Add oil as needed to bring the level to the upper
mark on the dipstick.
21. Dispose of used filter and oil properly.
87
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MAINTENANCE
Transmission Oil
Always check and change the transmission oil at the intervals outlined
in the Periodic Maintenance Chart beginning on page 75. Maintain the
oil level at the bottom of the fill plug hole threads. We recommend the
use of Polaris Premium AGL Synthetic Gearcase Lubricant. See page
133 for the part numbers of Polaris products.
The fill plug is located on the left side of the ATV, under the rear fender,
behind the wheel.
The drain plug is located on the right side of the gearcase, on the right
side of the ATV, behind the wheel well.
Fill Plug
Drain Plug
Transmission Oil Level
1. Position the vehicle on a level
Fill Plug
surface.
2. Remove the fill plug.
3. Check the oil level. Add the
recommended oil as needed.
4. Reinstall the fill plug. Torque
to 20-25 ft. lbs. (27-34 Nm).
88
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MAINTENANCE
Transmission Oil
Transmission Oil Change
1. Remove the fill plug.
2. Place a drain pan under the
gearcase.
3. Remove the drain plug. Allow
the oil to drain completely.
4. Clean and reinstall the drain
plug. Torque to 20-25 ft. lbs.
(27-34 Nm).
Drain
Plug
5. Add 32 oz. (948 ml) of the
recommended oil.
6. Reinstall the fill plug. Torque to 20-25 ft. lbs. (27-34 Nm).
7. Check for leaks. Dispose of used oil properly.
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 75. We rec-
ommend the use of Demand Drive LT Premium Fluid. Use of other
fluids may result in improper operation of components. See page 133 for
the part numbers of Polaris products.
Maintain the fluid level at
the bottom of the fill hole
threads. See below for
capacity.
Fill
Plug
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.
Drain Plug
Fill Level
Demand Drive Capacities
Demand Drive with ADC
9.3 oz. (275 ml)
89
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MAINTENANCE
Front Gearcase (Demand Drive) Fluid
Fluid Level
1. Position the vehicle on a level surface.
2. Remove the fill plug. Check the fluid level.
3. Add the recommended demand drive fluid as needed to bring the
level to the bottom of the fill hole threads.
4. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
Fluid Change
1. Position the vehicle on a level surface.
2. Remove the fill plug.
3. Place a drain pan under the demand drive unit.
4. Remove the drain plug. Allow the fluid to drain completely.
5. Clean and reinstall the drain plug. Torque to 11 ft. lbs. (15 Nm).
6. Add the recommended fluid. See page 89 for capacity. Maintain the
fluid level at the bottom of the fill hole threads.
7. Reinstall the fill plug. Torque to 8-10 ft. lbs. (11-14 Nm).
8. Check for leaks.
9. Dispose of used fluid properly.
Active Descent Control (ADC) Fluid
Two fluid levels must be maintained on your vehicle, the demand drive
fluid and the ADC fluid. See page 89 for demand drive fluid mainte-
nance.
Check and change the ADC fluid level at the intervals outlined in the
Periodic Maintenance Chart beginning on page 75. Maintain the fluid
level between the minimum and maximum marks on the reservoir. We
recommend the use of Polaris ADC Fluid. See page 133 for the part
numbers of Polaris products.
NOTICE: Do not use brake fluid. Brake fluid will damage rubber components in
the hydraulic system.
90
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MAINTENANCE
Active Descent Control (ADC) Fluid
Fluid Level
1. Open the front box cover and pull open the
access door.
500 EFI
2. View the fluid level in the reservoir. If the
level is below the minimum mark, remove
the cap and add the recommended fluid.
3. Reinstall the cap securely. Secure the
access door and box cover.
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.
ADC Fluid Reservoir
800 EFI
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 reser-
voir. 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. Clean up any drips or spills.
91
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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 133 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 96.
2. Maintain the coolant level
between the minimum and
maximum marks on the bot-
tle (when the fluid is cool).
3. Add coolant as needed.
Recovery
Bottle
92
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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 pres-
sure 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.
93
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MAINTENANCE
Brakes
Hand Brake
The front and rear brakes are hydraulic disc brakes, activated by moving
the single brake lever toward the handlebar. 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 32.
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.
Auxiliary Foot Brake
The hydraulic auxiliary brake system requires no adjustment. Check the
brake fluid level frequently for the auxiliary brake system. See page 34.
94
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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.
2
1
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.
95
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MAINTENANCE
Steering Assembly
The steering assembly of the ATV 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 six screws on
the bottom of the footwell.
Screws
2. Use a flat screwdriver or
sidecutters to remove the
plastic rivets securing the
footwell to the fenders.
3. Remove the footwell.
Rivets
96
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MAINTENANCE
Tires
WARNING
Operating your ATV 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 134 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.
97
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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 service.
Nut Type
Nut Torque
Lug Nut
90 ft. lbs. (122 Nm)
27 ft. lbs. (37 Nm)
2-Piece Flange Nut
98
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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 fil-
ter 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.
99
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MAINTENANCE
Breather Filter/Hose (500 EFI)
The breather filter is on
the hose that runs
between the engine and
air box.
1. Remove the left side
panel. See page 96.
2. Remove the hose
clamps from the fil-
ter and pull the filter
out of the hoses.
Breather Filter
3. Inspect the filter for debris. Blow gently through the filter in the
direction of the arrow to check for clogging. Replace a damaged or
clogged filter.
4. Check the hoses for cracks, deterioration, abrasion, or leaks.
Replace as needed.
5. Reinstall the filter and hose clamps.
Tip: The filter is effective with the arrow pointing in either direction.
NOTICE: Operation of your vehicle without a breather filter can cause engine
damage. Always reinstall the breather filter after removing it for
service.
100
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MAINTENANCE
Fuse Replacement
If the engine stops or will not
start, or if you experience other
electrical failures, a fuse may
need replacement. Spare fuses are
provided in a compartment on the
top of the access door.
1. Open the front box cover 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
3. Secure the access door.
4. Secure the box cover.
Fuse Panel
5or6 15 20 20
101
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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 head-
lights frequently and replace burned out headlamps promptly. Always
make sure lights are adjusted properly for best visibility.
Headlight Lamp Replacement
When servicing a halogen lamp, avoid touching the lamp with bare fin-
gers. Oil from your skin leaves a residue, causing a hot spot that will
shorten the life of the lamp. If fingers do touch a lamp, clean it with
denatured alcohol.
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.
102
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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.
25 ft.
(7.6 m)
2" (5 cm)
1. Position the vehicle on a level surface with the headlight approxi-
mately 25 ft. (7.6 m) from a wall. Place the transmission in PARK.
2. Measure the distance from the floor to the center of the headlight
and make a mark on the wall at the same height.
3. Start the engine.Turn the headlight switch to high beam.
4. Observe the headlight aim on the wall. The most intense part of the
headlight beam should be two inches (5 cm) below the mark on the
wall. Include rider weight on the seat when measuring.
5. The adjustment knob is located on the right side of the headlight
pod. Adjust the beam to the desired position by turning the knob
either clockwise or counterclockwise.
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.
103
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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)
104
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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/Worklight (if equipped) Lamp
Replacement
1. Open the tailgate.
2. Remove the two screws near the
tailgate latch.
Screws
3. Grasp the entire taillight assembly
and pull it away from the vehicle.
4. Remove the harness connector
from the back of the light assem-
bly.
5. Turn the lamp counterclockwise to
remove it.
Lamp
6. Apply dielectric grease to the
socket and install the new lamp.
7. Reinstall the harness connector.
8. Test the light for proper operation.
9. Reinstall the taillight assembly.
10. Reinstall the two screws.
105
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MAINTENANCE
Spark Plugs
Spark Plug Recommendations
Refer to the specifications section beginning on page 134 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
plug for correct color. See page 107.
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.
106
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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.
107
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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 ATV to a dealer
before starting it, follow the steps outlined below.
1. Move the ATV 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 plug.
4. Turn the engine over several times using the electric start.
5. Dry the spark plug. Reinstall the plug or install a new plug.
6. Attempt to start the engine. If necessary, repeat the drying proce-
dure.
7. Take the ATV 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 112 for drying out the PVT.
108
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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.
Exhaust
Outlet
2. Place the transmission in
PARK.
3. Start the engine.
4. Quickly squeeze and release
the throttle lever several times
to purge carbon from the system.
Clean-Out Plug
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.
109
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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.
110
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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.
On Polaris ATVs, the approximate gear ratio difference between high
and low range is 1:2.25. This difference in gearing affects the operation
of the PVT, especially at speeds less than 7 MPH (11 km/h), due to the
system's dependence 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.).
111
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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
Low
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.
112
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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 ATV may have either a sealed battery, which requires little mainte-
nance, or a conventional battery. A sealed battery can be identified 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.
113
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MAINTENANCE
Battery
Battery Removal
1. Loosen the battery hold-down bolt.
2. Remove the battery cover.
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 ATV. Be careful not to tip a conventional
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.
114
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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 117 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. Install the battery cover.
8. Tighten the battery hold-down bolt.
9. Verify that cables are properly routed. Cables should be safely
tucked away at the front and rear of the battery.
115
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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.
Tip: Power plug leads may need to be bent down so that the battery cover can
be installed.
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 133 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.
116
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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 114.
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 115. 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.
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.
117
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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
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
118
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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.
119
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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 labels. Avoid directing the water stream at the follow-
ing items:
• Wheel bearings
• Radiator
• Transmission seals
• Brakes
• Cab and body panels
• Labels and decals
• Electrical components and wiring
If warning and safety labels are damaged, contact your Polaris dealer for
free replacement.
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.
120
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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.
121
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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 clean the vehicle as recommended. See
page 119.
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 83.
Air Filter / Air Box
1. Inspect and clean (or replace) the pre-cleaner and air filter. See page
99.
2. Clean the air box.
3. Drain the sediment tube.
4. Clean or replace the breather filter (if equipped). See page 100.
122
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MAINTENANCE
Cleaning and Storage
Storage Tips
Fluid Levels
Inspect the fluid levels. Add or change fluids as recommended in the
Periodic Maintenance Chart beginning on page 75.
• Demand drive unit (front gearcase)
• ADC fluid (ADC models) (change every two years)
• Rear gearcase (if equipped)
• Transmission
• Brake fluid (change every two years and any time the fluid looks dark
or contaminated)
• Coolant (test strength/fill)
Fog the Engine
1. Treat the fuel system with Polaris Carbon Clean. Follow the instruc-
tions on the container. Start the engine. Allow it to idle for several
minutes so the Carbon Clean reaches the injectors. Stop the engine.
2. Remove the spark plug and add 2-3 tablespoons of engine oil. To
access the plug hole, use a section of clear 1/4" hose and a small
plastic squeeze bottle filled with the pre-measured amount of oil.
Do this carefully. If you miss the plug hole, oil will drain from the
spark plug cavity into the hole at the front of the cylinder head, and
appear to be an oil leak.
3. Reinstall the spark plug. 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.
123
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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 75.
Battery Storage
See pages 116-117 for storage and charging procedures.
Storage Area/Covers
Set the tire pressure and safely support the ATV 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 ATV. Always
install accessories that are approved for ATV use. Please see your
Polaris dealer.
124
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MAINTENANCE
Transporting the ATV
Follow these procedures when
transporting the vehicle.
1. Stop the engine.
2. Place the transmission in
PARK.
3. Lock the parking brake.
4. Always secure the seat in the
1-up position to prevent loss
during transporting.
5. Secure the fuel cap and oil
cap.
6. Always tie the frame of the
ATV to the transporting unit
securely with suitable straps
or rope. Do not attach tie
straps to the front A-arm bolt
pockets.
7. Remove the key to prevent
loss during transporting.
125
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ADJUSTMENTS
Camber and Caster
The camber and caster are non-adjust-
able.
Rear Spring
The rear shock absorber spring is
adjusted by rotating the adjuster either
clockwise or counterclockwise to
increase or decrease spring tension.
Tip: Accessory springs are available through
your Polaris dealer.
Adjuster
126
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ADJUSTMENTS
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
127
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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
128
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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
64).
Driving at low RPM or
Drive at a higher speed or use low range more frequently.
ground speed (3-7 MPH) See page 112.
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 112. 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 51.
129
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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
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 plug(s)
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
Inspect, clean and/or replace spark
plug(s)
Incorrect spark plug gap or heat range
Old or non-recommended fuel
Incorrectly installed spark plug wires
Incorrect ignition timing
Set gap to specs or replace plugs
Replace with fresh recommended fuel
See your dealer
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
130
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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 plug(s)
Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Water present in fuel
See your dealer
Set gap to specs or replace plugs
Check all connections and tighten
Replace with new fuel
Recharge battery to 12.8 VDC
Inspect and replace
Low battery voltage
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
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
131
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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 plug(s)
Inspect, clean and/or replace spark
plug(s)
Worn or defective spark plug wires
Incorrect spark plug gap or heat range
Loose ignition connections
Low battery voltage
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
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.
132
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POLARIS PRODUCTS
Part
Number
Description
Engine Lubricant
2870791
2876244
2876245
Fogging Oil (12 oz. Aerosol)
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
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
2873602
2873603
2876144
2871653
2872276
2870465
2876251
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
2872073
2872348
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 (NyogelTM
)
Chain Lube, Aerosol (6.25 oz./185 ml)
Chain Lube, Aerosol (16 oz./473 ml)
Additives / Miscellaneous
Carbon Clean Plus
Fuel Stabilizer
DOT 4 Brake Fluid
2871326
2870652
2872189
2871956
2859044
LoctiteTM 565 Thread Sealant
Polaris Battery TenderTM Charger
133
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SPECIFICATIONS
Sportsman X2 500 EFI
Maximum Weight Capacity
705 lbs. (320 kg) (includes operator, passen-
ger, cargo, accessories)
Dry Weight
798 lbs. (362 kg) (base model)
90 lbs. (41 kg)
Front Rack/Storage Box Capacity
Rear Storage Box Capacity
Receiver Hitch Tongue Capacity
400 lbs. (181 kg)
120 lbs. (55 kg) (Rear box capacity and
tongue weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating
Unbraked Trailer Towing Capacity
Overall Length
1225 lbs. (555.7 kg) on level ground
1995 lbs. (905 kg)
93 in. (236 cm)
48 in. (122 cm)
48 in. (122 cm)
57 in. (145 cm)
11 in. (28 cm)
Overall Width
Overall Height
Wheelbase
Ground Clearance
Minimum Turning Radius
Fuel Capacity
82 in. (208 cm) unloaded
6 gal. (22.7 l)
Engine Oil Capacity
Coolant Capacity
Demand Drive Fluid Capacity
Transmission Oil Capacity
Engine
2 qts. (1.9 l)
2.7 qts. (2.5 l)
9.3 oz. (275 ml)
32 oz. (948 ml)
EH50PLE
Displacement
499 cc
Bore x Stroke
92 x 75
Alternator Output
Compression Ratio
Fuel System
350 w
10.2:1
Electronic Fuel Injection
Electronic Ignition
10 +/- 1 BTDC @ idle
NGK BKR6E
Ignition System
Ignition Timing
Spark Plug
Spark Plug Gap
.035+0.0/-0.004 in. (0.9+0.0/-0.1 mm)
Dry Sump
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 8.75" (22 cm) travel
* Based on EU Directive 76/432/EC
134
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SPECIFICATIONS
Sportsman X2 500 EFI
Transmission
Automatic EBS (Engine Braking System)
with E-Z Shift H/L/N/R/P
Gear Reduction, Low
Gear Reduction, Reverse
Gear Reduction, High
Drive Ratio, Front
Tires/Pressure, Front
Tires/Pressure, Rear
Brakes, Front
23.91:1
21.74:1
10.57:1
3.82:1
25x8-12 / 5 psi
25x11-12 / 5 psi
Single-Control Hydraulic Disc
Single-Control Hydraulic Disc
Foot-Activated Hydraulic Disc
Hydraulic lock, all wheel
Brakes, Rear
Brake, Auxiliary
Brake, Parking
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 (EBS Models)
Altitude
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
(0-6000)
10 WH
Blue/Green
Yellow
PN 3234451
EBS
PN 3234356
PN 5630710 PN 7041157
1800-3700
10 RH
Blue/Green
Yellow
PN 3234451
EBS
PN 3234356
(6000-12000) PN 5630709 PN 7041157
*EBS models require no helix/spring adjustment
135
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SPECIFICATIONS
Sportsman X2 800 EFI
Maximum Weight Capacity
705 lbs. (320 kg) (includes operator, passen-
ger, cargo, accessories)
Dry Weight
830 lbs. (376 kg) (base model)
90 lbs. (41 kg)
Front Rack/Storage Box Capacity
Rear Storage Box Capacity
Receiver Hitch Tongue Capacity
400 lbs. (181 kg)
150 lbs. (68 kg) (Rear box capacity and
tongue weight not to exceed 400 lbs./181 kg)
Hitch Towing Rating
Unbraked Trailer Towing Capacity*
Overall Length
1500 lbs. (680.4 kg) on level ground
1995 lbs. (905 kg)
93 in. (236 cm)
48 in. (122 cm)
48 in. (122 cm)
57 in. (145 cm)
11 in. (28 cm)
Overall Width
Overall Height
Wheelbase
Ground Clearance
Minimum Turning Radius
Fuel Capacity
82 in. (208 cm) unloaded
6 gal. (22.7 l)
Engine Oil Capacity
Coolant Capacity
Demand Drive Fluid Capacity
Transmission Oil Capacity
Engine
2 qts. (1.9 l)
3.4 qts. (3.2 l)
9.3 oz. (275 ml)
32 oz. (948 ml)
EH0760LE
Displacement
760 cc
Bore x Stroke
80x76
Alternator Output
Compression Ratio
Fuel System
500 Watts @3000 RPM
10:1
Electronic Fuel Injection
Electronic Ignition
Variable - ECU controlled
RC7YC
Ignition System
Ignition Timing
Spark Plug
Spark Plug Gap
.035 in. (0.9 mm)
Pressurized Wet Sump
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 8.75" (22 cm) travel
* Based on EU Directive 76/432/EC
136
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SPECIFICATIONS
Sportsman X2 800 EFI
Transmission
Automatic EBS (Engine Braking System)
with E-Z Shift H/L/N/R/P
Gear Reduction, Low
Gear Reduction, Reverse
Gear Reduction, High
Drive Ratio, Front
Tires/Pressure, Front
Tires/Pressure, Rear
Brakes, Front
23.91:1
21.74:1
8.28:1
3.82:1
25x8-12 / 5 psi
25x11-12 / 5 psi
Single-Control Hydraulic Disc
Single-Control Hydraulic Disc
Foot-Activated Hydraulic Disc
Hydraulic lock, all wheel
Brakes, Rear
Brake, Auxiliary
Brake, Parking
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 (EBS Models)
Altitude
Shift
Weight
Drive Clutch
Spring
Driven
Clutch
Spring
Helix*
Meters
(Feet)
0-1800
21-74
66-56-33
BA500
(0-6000)
PN 5632117
Red/White
Red
PN 7043427 PN 3234452
EBS
1800-3700
(6000-12000)
21-70.5
PN 5632106
PN 3234604
*EBS models require no helix/spring adjustment
137
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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 All Terrain Vehicle (ATV) 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 ATV IS REGISTERED WITH POLARIS.
Initial dealer preparation and set-up of your ATV is very important in ensuring trouble-
free operation. Purchasing a machine in the crate or without proper dealer set-up will
void your warranty coverage.
138
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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 ATV that
has been altered structurally, modified, neglected, improperly maintained, used for rac-
ing, 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, components or the ATV 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 ATV. The exclusive remedy for breach of this warranty shall
be, at Polaris' exclusive option, repair or replacement of any defective materials, or com-
ponents or products. THE REMEDIES SET FORTH IN THIS 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 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.
139
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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 ATV requires warranty service, you must take it to a Polaris dealer authorized to
repair Polaris ATVs. When requesting warranty service you must present your copy of
the Warranty Registration 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 for your ATV.
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 8340.1(c) for at least 1000 hours when subjected to normal use and
when maintenance and installation are in accordance with Polaris recommendations.
140
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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.
141
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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
142
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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.
143
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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
144
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MAINTENANCE LOG
DATE
MILES (KM)
OR HOURS
TECHNICIAN
SERVICE PERFORMED / COMMENTS
145
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