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1. Component Condition SPN FMI Ignition Coil Primary Driver 1 MAG Driver Circuit Short to B 1268 3 Ignition Coil Primary Driver 2 PTO Driver Circuit Short to B 1269 3 Fuel Pump Driver Circuit Driver Circuit Open Grounded 1347 5 Driver Circuit Short to B 1347 3 Driver Circuit Grounded 1347 4 Fan Relay Driver Circuit Driver Circuit Open Grounded 1071 5 Driver Circuit Short to B 1071 3 Driver Circuit Grounded 1071 4 Idle Air Control Driver Circuit Open Grounded 634 5 Driver Circuit Short to B 634 3 Driver Circuit Grounded 634 4 Position Out of Range 634 7 Starter Enable Circuit Driver Circuit Open Grounded 1321 5 Driver Circuit Short to B 1321 3 Driver Circuit Grounded 1321 4 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 520208 3 Driver Circuit Grounded 520208 4 All Wheel Drive Control Driver Circuit Open Grounded 520207 5 Driver Circuit Short to B 520207 3 Driver Circuit Grounded 520207 4 System Power Voltage Too High 168 3 Voltage Too low 168 4 Throttle Safety Signal Voltage Too High 520194 3 Voltage Too Low 520194 4 Signal Out of Range 520194 2 Throttle Stuck 520194 7 Active Descent Control System Driver Circuit Open Grounded 520203 5 Driver Circuit Short to B 520203 3 Driver Circuit Grounded 520203 4 Idle Speed Speed Too High 520211 3 Speed Too Low 520211 4 43 FEATURES AND CONTROLS I
2. 112 PVT Systemes isase ei 110 112 R Rack Compartment Front 46 Registration Warranty 134 Reverse Operation 61 Reverse Override Switch 24 Rider Information Center 36 41 Riding Area cee eee 50 RAGING Gear ss weds dew canned ends 8 9 S Safe Operation Practices 49 Safety Labels 20 23 Safety Training 7 Safetv Warnings 10 19 Safetv Winch Maintenance 76 Severe USE nisa sie gueines 78 Shock Loading the Winch 74 75 Side Panel Removal 95 Sidehilling L cireccsssnesss 56 Signal Words e002 edie sa kesa 4 Spark Arrester 0000 109 Spark Plug Inspection 106 107 Spark Plug Recommendations 106 Spark Plugs 106 107 Speedometer 34 Spring Adjustment Shock 113 Starting the Engine 51 Steering Assemblv 90 94 SOM GE 64 06 atira enS 120 123 Storage Tips 122 123 146 S Switches 4X4 Switch 00 24 32 Engine Stop Switch 25 Headlight Switch 24 Main Key Switch 25 Mode Switch 24 Reverse Override Switch 24 Stop Switch 000 25 T Tarllight 53 6445 co eeaeed bina oa 105 Throttle Bodv Adjustment 114 Throttle Cable Freeplav 114 115 Throttle Lever 0000 26 Tire Tread Depth neresi cuidei 96 MOS
3. 34 45 K Key SWitChins e sicat diss ie sedis ards 8B 25 K Tifftia eee 58 INDEX L Lights Headlight Housing Replacement 104 Headlight Lamp 101 High Beam Adjustment 102 Low Beam Adjustment 103 Lower Headlamp Replacement 105 Taillight Brakelight 105 Low Beam Adjustment 103 Low Range Use 112 Lower Headlamp Replacement 105 Lubrication Guide 82 M Maintenance Chart 78 81 Master Cylinder 28 Metric Display 38 Mode Switch 24 Modifications 0 9 N Noise Emission Control Svstem 77 O Oil Engine it tidol ie 83 85 Rear Gearcase 88 89 Transmission 86 Oil and Filter Change 84 85 Oil Change Rear Gearcase 89 Transmission 86 Oil Level Engine isa i ki See ea 83 Rear Gearcase 88 Transmission 86 Oil Recommendations 83 Operation on Public Lands 77 Override Switch 00 24 145 INDEX P Parking Brake 29 Parking on an Incline 57 Periodic Maintenance Chart 78 81 Polaris Product List 129 Polishing the Vehicle 121 Power Steering ss ess ease eae sais 31 Power Steering Unit Cleaning 90 Pre Ride Checklist 48 PVT Break In oi oss cee ens ens 47 PVT Drying
4. 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 screw is located on the right side of 3 AO an the headlight pod To adjust the beam loosen the screw Adjust the headlamp to the desired position then tighten the screw 102 MAINTENANCE Lights Low Beam Adjustment The low beam can be adjusted slightly upward or downward 1 Loosen the phillips screw located at the rear of the headlamp 2 Tilt the headlamp upward or downward 3 Tighten the screw 103 MAINTENANCE Lights Headlight Housing Replacement 1 2 104 Remove the five 5 headlight pod screws Lift the pod cover and disconnect the speedometer harnesses from the speedometer Unplug the headlamp from the wiring harness Use a small screwdriver to remove the o rings from the headlight mounting tabs Pull the headlight housing up to release it from the locking tabs Carefully pull the assembly up and out of the pod Reverse the steps to install the new housing and reassemble the pod MAINTENANCE Lights Lower Headlamp Replacement 1 Turn the back of the headlight harness counter clockwi
5. Swsweabu da san eds 9 F Fluid Bias d a ti 28 Coolant eer ee 90 92 Demand Drive 87 Engine Oil os l ie woot 83 85 Rear Gearcase 88 89 Transmission Oil 86 Fluid Change Demand Drive 87 Engine Oil 5 636s cece 84 85 Rear Gearcase 000 89 Transmission 86 F Fluid Level Demand Drive 87 Engine Oil i cos cic taeceecacss 83 Rear Gearcase 88 Transmission 86 Foot Brake Auxiliarv 30 Footwell Removal 95 Front Compartment 46 Front Gearcase Demand Drive 87 Front Rack Compartment 46 Fuel Safety L wisszsar ve oe se siss 11 Fuel Tank Cap 00 31 Fuse Replacement 100 G Gasoline Handling 11 Gauge Code Definitions 42 45 Gauge Digital Analog 34 41 Gear Selectot as insect aes antes 25 Gearcase Oil Rear 88 89 GIOVES s as ay cats cha eae de only 9 H Hand Brake aie kid i otba 93 Handlebar Adjustment 113 Hauling Cargo 62 64 Headlight Housing Replacement 104 Headlight Lamp Replacement 101 Headlight Switch 24 Helmet siii s seegioia l i iebu x 8 High Beam Adjustment 102 High Range Use 112 l Idle RPM Adjustment 114 Immersion es ne eee eae 108 Indicator Lamps 35 Instrument Cluster
6. Engine warm Idle RPM 1200 50 Throttle Body Size Mikuni Dual Bore 42 mm Spark Plug Type Gap REA6MC 035 in 0 9 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 130 SPORTSMAN 850 SPORTSMAN 850 SP SPECIFICATIONS Transmission H L N R P Gear Reduction Low 5 034 1 Gear Reduction Reverse 4 508 1 Gear Reduction High 2 367 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 7 1 Tires Pressure Front 26x8 14 7 psi 48 3 kPa Tires Pressure Rear 26x10 14 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital Analog Clutching Altitude Shift Drive Clutch Driven Helix Weight Spring Clutch Spring Meters 0 1800 24 63 Orange Red White 58 66F 45 BA Feet 0 6000 PN 5632215 PN 7044279 PN 3235088 PN 3235630 1800 3700 24 60 Orange Red White 58 66F 45 BA 6000 12000 PN 5632216 PN 7044279 PN 3235088 PN 32356
7. and always follow proper operating procedures as outlined in this manual See page 60 Skidding or Sliding Skidding or sliding can cause loss of control or overturn if tires regain traction unexpectedly On slippery surfaces such as ice or loose gravel travel slowly and use extra caution to reduce the chance of skidding or sliding Do not operate on excessively slippery surfaces 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 59 e Travel slowly e Balance your weight carefully e Avoid sudden movements e Maintain a slow and steady forward motion Do not make sudden turns or stops and do not make sudden throttle changes Wet brakes may have reduced stopping ability After leaving water test the brakes Apply them lightly several times while driving slowly The friction will help dry out the pads 17 SAFETV Safetv Warnings Improper Cargo Loading Overloading the ATV or carrving towing cargo improperlv mav cause changes in handling which could cause loss of control or an accident e Never exceed the stated load capacity for this ATV e Cargo should be properly distributed and securely attached e Reduce speed when carrying cargo or pulling a trailer A
8. fittings gt Engine oil change 100 H 6M 1000 1600 Change the oil and filter gt Demand drive fluid 100 H 12 M 1000 1600 Change fluid normal use gt Rear gearcase oil 100 H 12 M 1000 1600 Change fluid gt Transmission oil 100 H 12M 1000 1600 Change fluid gt Perform these procedures more often for vehicles subjected to severe use E Emission Related Service D Have an authorized POLARIS dealer perform these services 80 Periodic Maintenance Chart MAINTENANCE Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km D Fuel system 100 H 12M 1000 1600 Cycle key to pressurize fuel E pump check for leaks at fill cap fuel lines rail and fuel pump replace lines every two years gt Engine mounts 100 H 12M 1000 1600 Inspect Exhaust muffler 100 H 12M 1000 1600 Inspect pipe D ISpark plug 100 H 12M 1000 1600 Inspect replace as needed E gt Wiring 100 H 12M 1000 1600 Inspect for wear routing security apply dielectric grease to connectors subjected to water mud etc D Clutches drive 100H 12M 1000 1600 Inspect clean replace worn and driven parts D Front wheel 100 H 12M 1000 1600 Inspect replace as needed bearings D Brake fluid 200 H 24M 2000 3200 Change every two years Spark arrester 300 H 36 M 3000 4800 Clean out gt Coolant 60 M Replace
9. requires that this spark arrester be installed and functional when the vehicle is operated on public lands Operation of off road vehicles on public lands in the U S A is regulated by 43 CFR 420 Violations are subject to monetary penalties Federal regulations can be viewed online at www gpoaccess gov ecfr Crankcase Emission Control System This engine is equipped with a closed crankcase system Blow by gases are forced back to the combustion chamber by the intake system All exhaust gases exit through the exhaust system Exhaust Emission Control System Exhaust emissions are controlled by engine design An electronic fuel injection EFI system controls fuel delivery The engine and EFI com ponents are set at the factory for optimal performance and are not adjustable The emissions label is located on the right front frame of the vehicle Electromagnetic Interference This spark ignition system complies with Canadian standard ICES 002 This vehicle complies with the EMC requirements of European direc tives 97 24 EC and 2004 108 EC Non ionizing Radiation This vehicle emits some electromagnetic energy People with active or non active implantable medical devices such as heart monitoring or controlling devices should review the lim itations of their device and the applicable electromagnetic standards and directives that apply to this vehicle 77 MAINTENANCE Periodic Maintenance Chart Careful periodic maintenance wil
10. 5682 030 in 0 76 mm Lubrication System Wet Sump Driving System Type Automatic PVT POLARIS Variable Transmission Front Suspension Dual a arm with 9 2 23 cm travel Rear Suspension Progressive rate with 10 2 26 cm travel Based on EU Directive 76 432 EC 132 SPECIFICATIONS SPORTSMAN XP 1000 Transmission H L N R P Gear Reduction Low 5 034 1 Gear Reduction Reverse 4 508 1 Gear Reduction High 2 367 1 Drive Ratio Front 3 818 1 Drive Ratio Rear 3 7 1 Tires Pressure Front 26x8 14 7 psi 48 3 kPa Tires Pressure Rear 26x10 14 7 psi 48 3 kPa Brakes Front Rear Single Control Hydraulic Disc All Wheel Brakes Auxiliary Foot Activated Hydraulic Disc Rear Wheel Brake Parking Hydraulic lock all wheel Headlight 1 Single Beam on Headlight Pod 50 watt 2 Single Beam on Bumper 50 watt Taillights 7 watts Brake Light 27 watts Instrument Cluster Digital Analog Clutching Altitude Shift Drive Driven Helix Weight Clutch Clutch Spring Spring Meters 0 1800 24 70 Orange Black White 58 66F 45 BA Feet 0 6000 PN 5633136 PN 7044279 Lettering PN 3235630 PN 7044086 1800 3700 24 60 Purple Black White 58 66F 45 BA 6000 12000 PN 5632216 PN 7043805 Lettering PN 3235630 PN 7044086 EBS models require no helix spring adjustment 133 WARRANTV Limited Warrantv POLAR
11. And Remedies This warranty excludes damages or failures caused by abuse accident fire or any other cause other than a defect in materials or workmanship and provides no coverage for consumable components general wear items or any parts exposed to friction surfaces stresses environmental conditions and or contamination for which they were not designed or not intended including but not limited to the following items Finished and unfinished surfaces Carburetor Throttle body components Engine components Drive belts Hydraulic components and fluids Circuit breakers Fuses Wheels and tires Suspension components Brake components Seat components Clutches and components Steering components ee o o o o o o o e e o o o Batteries Electronic components Light bulbs Sealed beam lamps Spark plugs Filters Sealants Lubricants Coolants Bushings Bearings Lubricants and Fluids 1 Mixing oil brands or using non recommended oil may cause engine damage We recommend the use of POLARIS engine oil 2 Damage or failure resulting from the use of non recommended lubricants or fluids is not covered by this warranty This warranty provides no coverage for personal loss or expense including mileage transportation costs hotels meals shipping or handling fees product pick up or delivery replacement rentals loss of product use loss of profits or loss of vacation or personal time THE EXCLUSIVE REMEDY FOR BREAC
12. Antifreeze 50 50 Premix added Any time the cooling system has been drained for maintenance or repair replace the coolant with fresh Antifreeze 50 50 Premix 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 Remove the front rack 2 Remove the pressure cap 3 Using a funnel slowly add coolant through the radiator filler neck 4 Reinstall the pressure cap Use of a non standard pressure cap will not allow the recovery system to function properly Contact your dealer for the correct replacement part 5 Reinstall the front rack 92 MAINTENANCE Brakes Hand Brake The front and rear brakes are hvdraulic disc brakes activated bv 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 likelv and the diaphragm should be replaced To ensure proper diaphragm operation alwavs 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 l
13. Debris lodged in screen Clean the screen Plugged Radiator Use a garden hose to flush anv debris from the radiator fins NOTE High pres sure washers can deform the radiator fins and reduce cooling efficiencv 128 POLARIS PRODUCTS iit Description Engine Lubricant 2870791 Fogging Oil 12 oz Aerosol 2876244 PS 4 Full Synthetic 5W 50 4 Cycle Oil qt 95 l 2876245 PS 4 Full Synthetic 5W 50 4 Cycle Oil gal 3 8 l 2878920 PS 4 Extreme Duty Synthetic 10W 50 4 Cycle Oil qt 95 1 2878919 PS 4 Extreme Duty Synthetic 10W 50 4 Cvcle Oil gal 3 8 1 Gearcase Transmission Lubricants 2878068 Aarde Synthetic Gearcase Lubricant amp Transmission Fluid 2878069 TANTI Te Gearcase Lubricant amp Transmission Fluid gal 3 2877922 Demand Drive Fluid qt 95 I 2877923 Demand Drive Fluid gal 3 8 l 2870465 Pump for Gallon 3 8 I Jug Coolant 2880514 Antifreeze 50 50 Premix qt 95 l 2880513 Antifreeze 50 50 Premix gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season Grease 2871322 All Season Grease 3 0z 89 ml cartridge 2871423 All Season Grease 14 0z 414 ml cartridge 2876160 ATV Angle Drive Fluid qt 95 I 2872276 ATV Angle Drive Fluid 2 5 gal 9 5 l 2871460 Premium Starter Grease 2871515 U Joint Grease 3 0z 89 ml cartridge 2871551 U Joint Grease 14 02 414 ml cartridge 287132
14. NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign indicates an action NOT to take in order to avoid a hazard The Mandatory Action Sign indicates an action that NEEDS to be taken to avoid a hazard INTRODUCTION Failure to heed the warnings and safety precautions contained in this manual can result in severe injury or death A POLARIS ATV is not a toy and can be hazardous to operate This vehicle handles differently than other vehicles such as motorcycles and cars A collision or rollover can occur quickly even during routine maneuvers like turning or driving on hills or over obstacles if you fail to take proper precautions e Read this owner s manual Understand all safety warnings precautions and operating procedures before operating a POLARIS ATV Keep this manual with the ATV e Never operate an ATV without proper instruction Take a training course e This vehicle is an ADULT VEHICLE ONLY Operation is prohibited for anyone under 16 years of age e 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 European Vibration and Noise The driver perceived noise and hand arm and whole body vibration lev els of this machinery is measured per prEN 15997 The operating conditions of the machinery during testing The vehicles were in like new condition The environment was con trolle
15. Store the battery in a cool dry place 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 materials They do not allow enough ventilation to prevent condensation and may promote corrosion and oxidation 123 MAINTENANCE Transporting the ATV 1 Stop the engine Place the transmission in PARK Lock the parking brake Secure the fuel cap oil cap and seat kal IE a Alwavs tie the frame of the ATV to the transporting unit securelv with suitable straps or rope Do not attach tie straps to the front A arm bolt pockets racks or handlebars 6 Remove the key to prevent loss during transporting Accessories Auxiliary power outlets provide 12 volt power for operating accessories 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 TROUBLESHOOTING Drive Belt Wear Burn Possible Cause Solution Driving onto a pickup or tall trailer in high range Use low range during loading Starting out going up a steep incline Use low range or turn around using the K turn see page 58 Driving at low RPM or ground speed 3 7 MPH Drive at a higher speed or
16. Yoke miles before long periods of storage or after A Arms Front and Rear All Season Grease or grease conforming to NLGI No 2 Grease fittings after extreme use or if suspension becomes squeaky Front Prop Shaft Yoke 82 MAINTENANCE Engine Oil Qil Recommendations POLARIS recommends the use of POLARIS PS 4 Full Synthetic 5W 50 4 cycle oil or a similar oil for this engine See the table on page 82 for fluid recommendations capacities and plug torques Oil may need to be changed more frequently if POLARIS oil is not used Always use 5W 50 oil Follow the manufacturer s recommendations for ambient temperature operation See page 129 for the part numbers of POLARIS products NOTICE Mixing brands or using a non recommended oil may cause serious engine damage Always use the recommended oil Never substitute or mix oil brands Oil Level Check the oil level when the engine is cold Never check the oil with the engine running 1 Position the vehicle on a level surface 2 Access the oil dipstick and fill tube from the left side of the ATV Remove the dipstick Wipe it dry with a clean cloth Full b sa 3 Reinstall and tighten the dipstick O00 ang Dipstick 4 Remove the dipstick and check the oil level 5 Add the recommended fluid as needed Maintain the oil level in the safe range between the FULL and ADD marks Do not overfill 6 Reinstall and tighten the dip
17. coolant D Valve clearance 1000 H 10000 Inspect adjust E 16000 D Toe adjustment Inspect periodically adjust when parts are replaced Headlight aim Adjust as needed 81 MAINTENANCE Lubrication Guide Check and lubricate all components at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 Items not listed in the chart should be lubricated at the General Lubrication interval The a arms and lower control arms are lubricated at the factorv 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 pressure washing or submerging Item Recommended Capacity Fill Plug Drain Plug See Lubricant at Fluid Torque Torque Page Change Engine Oil PS 4 5W 50 4 Cycle 2 qt 1 9 I 12 ft lbs 83 Oil 16 Nm Transmission AGL Gearcase 37 oz 10 14 ft lbs 10 14 ft lbs 86 Oil Lubricant amp 1100 ml 14 19 Nm 14 19 Nm Transmission Fluid Demand Drive Demand Drive Fluid 9 3 oz 8 10 ft lbs 11 ft lbs 87 Fluid Front 275 ml 11 14 Nm 15 Nm Gearcase Rear ATV Angle Drive 7 1 02 10 14 ft lbs 10 14 ft lbs 88 Gearcase Oil Fluid or GL5 80 90 210 ml 14 19 Nm 14 19 Nm weight gear lube Brake Fluid DOT 4 Brake Fluid 28 Front Prop U Joint Grease Grease fittings 3 pumps maximum every 500 Shaft
18. ete sia ee pala 62 64 Caster Adjustment 113 Check Engine Indicator 41 Cleaning and Storage 120 123 CV OUI A TA i da wrens 9 Clutching BOO ees geste s hack wach eb de 131 XP 1000 assi ea s siwi 133 Cold Weather Operation 51 Consumer Product Safety 7 Coolant Bottle 91 Coolant Radiator 92 Cooling System 90 92 Crankcase Emission Control System 77 144 D Demand Drive Fluid 87 Diagnostic Codes 42 45 Disengaging Active Descent Control 33 Display Units Standard Metric 38 Drive Belt Wear Burn 125 Drivetrain Break In 47 Driving Downhill 57 Driving in Reverse 61 Driving on a Sidehill 56 Driving on Slipperv Surfaces 54 Driving Over Obstacles 60 Driving Procedures 52 Driving Through Water 59 Driving Uphill 55 E Electromagnetic Interference 77 Electronic Power Steering 31 Emissions Limited Warranty 138 140 Engaging 4X4 LL 33 Engaging Active Descent Control 33 Engine Break In 47 Engine Fogging 123 Engine OU i nesae 83 85 Equipment Modifications 9 Error Codes Engine 41 Etiquette Trail Riding 50 Exhaust Emission Control System 77 Extreme Use Battery 31 Eve Protections
19. headlights frequently and replace burned out headlamps promptly 18 SAFETV Safetv Warnings Operating a Damaged ATV Operating a damaged ATV can result in an accident After anv overturn or accident have a qualified service dealer inspect the entire machine for possible damage including but not limited to brakes throttle and steering svstems Phvsical Skills Safe operation of this rider active vehicle requires good judgement and physical skills Persons with cognitive or physical disabilities who operate this vehicle have an increased risk of overturn and loss of control Hot Exhaust Systems Exhaust system components are very hot during and after use of the vehicle Hot components can cause burns and fire Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Use caution when traveling through tall grass especially dry grass Unauthorized Use of the 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 19 SAFETV Safetv Labels and Locations Warning labels have been placed on the vehicle for vour 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 informatio
20. 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 indicator master cylinder before each ride Cylinder Window 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 win dow on the top of the master cylinder The eye will appear dark when the fluid level is full When fluid is low the eye will be clear 4 Ifthe fluid level is low remove the cover screws and add fluid to the fill line Do not overfill Use DOT 4 brake fluid only 5 Reinstall the cover Torque screws to 7 in Ibs 8 Nm 28 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 w
21. quickly turn the winch ON and OFF repeatedly jogging This puts extra load on the winch winch cable and generates excessive heat from the motor This is a form of shock loading Never tow a vehicle or other object with your winch Towing an object with a winch produces shock loading of the cable even when towing at slow speeds Towing from a winch also positions the towing force high on the vehicle This can cause instability of the vehicle and possibly lead to an accident WINCH GUIDE Shock Loading 4 Never use recovery straps with your winch Recovery straps are designed to stretch and can store energy This stored energy in the recovery strap is released if a winch cable fails making the event even more hazardous Similarly never use elastic bungie cords for winching 5 Never use the winch to tie down a vehicle to a trailer or other transportation vehicle This type of use also causes shock loading that can cause damage to the winch winch cable or vehicles used Your winch cable is designed and tested to withstand the loads produced by the winch motor when operated from a stationary vehicle Always remember that the winch and winch cable are NOT designed for shock loading 75 WINCH GUIDE Winch Maintenance and Service Safetv WARNING Improper or lack of winch maintenance and service could lead to SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Always inspect your win
22. stopping move your vehicle to the edge of the trail as far as possible to allow others to pass safely 50 OPERATION Starting the Engine Position the vehicle on a level surface outdoors or in a well ventilated area Place the transmission in PARK Lock the parking brake The starter interlock will prevent the engine from starting if the transmission is in gear and the brake is not engaged Sit on the vehicle and move the engine stop switch to RUN Do not press the throttle while starting the engine Turn the ignition kev past the ON position to engage the starter Activate the starter for a maximum of five seconds releasing the kev when the engine starts If the engine does not start return the kev to the OFF position and wait five seconds before attempting to start again Activate the starter for another five seconds if necessarv Repeat this procedure until the engine starts NOTICE Operating the vehicle immediatelv 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 vear round check the oil level frequentiv A rising oil level could indicate the accumulation of contaminates such as water or excess fuel in the bottom of the crankcase Water in the bottom of the crankcase can lead to engine damage and must be drained Water accumulation increases as outside temperature decreases 51 OPERATION Drivin
23. storage and recharge as needed to maintain a full charge POLARIS recommends maintaining battery charge by using a POLARIS Battery 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 129 for the part numbers of POLARIS products 117 MAINTENANCE Batterv Batterv Charging The following battery charging instructions apply only to the installation 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 The battery should be disconnected from a load or charger for at least two hours before checking voltage Check the batt
24. that is available to you and your eligible family members This training is included in the purchase price of your ATV You were also provided with printed materials that explain safe operating procedures You should review this information on a regular basis If you purchased a used POLARIS ATV in the United States you can enroll in the ATV RiderCourse for a fee Call ATV Enrollment Express at 800 887 2887 or visit www atvsafety org If you purchased a POLARIS ATV outside the United States please contact your dealer or local law enforcement agencies for information about safety training A POLARIS ATV is an off road vehicle Familiarize yourself with all laws and regulations concerning the operation of this vehicle in your area We strongly advise you to strictly follow the recommended maintenance program outlined in your owner s manual This preventive maintenance program is designed to ensure that all critical components on your vehi cle are thoroughly inspected at specific intervals FOR MORE INFORMATION ABOUT ATV SAFETY in the United States 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 SAFETV Safe Riding Gear Alwavs wear appropriate clothing when riding an ATV Wear protective clothing for comfort and to reduce the chance of injurv Helmet Eve Protection Long Sleeves Gloves Long Pants Helmet Wea
25. tire pressure Never operate a damaged ATV After any overturn or accident have a qualified service dealer inspect the entire machine for possible damage Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Do not touch hot exhaust system components Always keep combustible materials away from the exhaust system Always remove the ignition key when the vehicle is not in use to prevent unauthorized use 49 OPERATION Know Your Riding Area Tread Lightly Familiarize yourself with all laws and regulations concerning the operation of this off road vehicle in your area Respect the environment in which you ride Find out where the designated riding areas are by contacting your POLARIS dealer a local riding club or local officials Help keep our trails open for recreational vehicle use As an off road enthusiast you represent the sport and can set a good example or a poor example for others to follow Tread lightly Operate with respect for the terrain avoid littering and always stay on the designated trails Trail Etiquette Always practice good etiquette when riding Allow a safe distance between your vehicle and other vehicles operating in the same area Communicate to oncoming operators by signaling the number of vehicles in your group When
26. 30 EBS models require no helix spring adjustment 131 SPECIFICATIONS SPORTSMAN XP 1000 Maximum Weight Capacitv 575 Ibs 261 kg includes operator cargo and accessories Dry Weight 767 lbs 347 9 kg Fuel Capacity 5 25 gal 201 Engine Oil Capacitv 2 qts 1 9 1 Coolant Capacitv 2 qts 1 9 1 Rear Gearcase Oil Capacitv 7 1 oz 210 ml Demand Drive Fluid Capacitv 9 3 oz 275 ml Transmission Oil Capacitv 37 oz 1100 ml Front Rack Storage Box Capacity 120 lbs 54 kg Rear Rack Capacity 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO952LE Displacement 952 cc Bore x Stroke 90 5 x 74 Alternator Output 475w 1200 RPM Peak 630w Compression Ratio 11 1 Starting System Electric Ignition System Electronic Fuel Injection Ignition Timing 6 5 BTDC 1200 RPM Engine warm Idle RPM 1200 50 Throttle Body Size Mikuni Dual Bore 42 mm Spark Plug Type Gap AUTOLITE
27. 5 2 Remove the fill plug Check the oil level 3 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 4 Reinstall the fill plug Torque to specification 5 Reinstall the footwell Oil Change 1 Remove the footwell 2 Place a drain pan under the gearcase Remove the drain plug Allow the oil to drain completely ba Clean and reinstall the drain plug Torque to specification gt A Remove the fill plug Add the proper amount of the recommended oil Reinstall the fill plug Torque to specification Check for leaks Reinstall the footwell Dispose of used oil properly cs 86 MAINTENANCE Front Gearcase Demand Drive Fluid See the table on page 82 for fluid recommendations capacities and plug torques Alwavs check and change the demand drive fluid at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 See page 129 for the part numbers of POLARIS products Change the front gearcase fluid everv 25 hours if the ADC unit is exposed to extreme use Extreme use includes anv of the following e operation in ADC mode for prolonged periods e constant ADC operation on hilly or mountainous terrain e ADC is the primary mode of all wheel drive operation Tip If the front gearcase is makes excessive noise during ADC operation change the demand drive fluid If the noise continues please see your POLARIS dealer for service Use the recom
28. 50 sp 10 XD N it S a N pa ar TIT MPH NS AP CZ L IA a Rider Information Center 34 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Indicator Lamps Lamp Indicates Condition When standard mode is selected speed displavs in Vehicle miles per hour Speed When metric mode is selected speed displavs in kilometers per hour Over This lamp flashes to indicate an overheated engine If Temperature the indicator stops flashing but remains illuminated the overheating condition remains and the system will automatically reduce engine power yr EPS Warning This indicator illuminates when the key is turned to the ON position and goes off when the engine is started If the light remains on after starting the engine the EPS system is inoperative See your authorized POLARIS dealer for service Neutral This lamp illuminates when the transmission is in neutral and the ignition key is in the ON position A High Beam This lamp illuminates when the headlamp switch is set to high beam 10000 U Check Engine This indicator appears if an EFl related fault occurs Do not operate the ATV if this warning appears Serious engine damage could result See your dealer 35 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center The rider informatio
29. 9 Dielectric Grease Nyogel Additives Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer 2872189 DOT 4 Brake Fluid 129 SPECIFICATIONS SPORTSMAN 850 850 SP Maximum Weight Capacitv 575 Ibs 261 kg includes operator cargo and accessories Dry Weight 759 Ibs 344 3 kg 850 767 lbs 347 9 kg 850 SP Fuel Capacity 5 25 gal 20 1 Engine Oil Capacity 2 qts 1 9 1 Coolant Capacitv 2 qts 1 9 1 Rear Gearcase Oil Capacitv 7 1 oz 210 ml Demand Drive Fluid Capacitv 9 3 oz 275 ml Transmission Oil Capacitv 37 oz 1100 ml Front Rack Storage Box Capacity 120 lbs 54 kg Rear Rack Capacity 240 Ibs 109 kg Receiver Hitch Tongue Capacity 150 Ibs 68 kg Rear rack load and tongue weight not to exceed 240 Ibs 109 kg Hitch Towing Rating 1500 Ibs 680 4 kg Unbraked Trailer Towing Capacity 1914 Ibs 868 kg Overall Length 83 25 in 211 cm Overall Width 47 6 in 121 cm Overall Height 50 75 in 129 cm Wheelbase 53 in 134 6 cm Ground Clearance 11 6 in 29 5 cm Minimum Turning Radius 84 in 213 cm unloaded Engine EHO850LE Displacement 850 cc Bore x Stroke 87 x 71 5 Alternator Output 475w 21200 RPM Peak 630w Compression Ratio 11 1 Starting Svstem Electric Ignition Svstem Electronic Fuel Injection Ignition Timing 6 5 BTDC 1200 RPM
30. ALWAYS e use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS For vour nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com be ti Polaris Industries Inc GD PesLARIS 2100 Highwav 55 Medina MN 55340 Part No 9925442 Rev 02 Printed in USA
31. Battery 20H Monthly 200 320 Check terminals clean test Fuel System 20H Monthly Inspect cycle key to pressurize fuel pump check lines and fittings for leaks and abrasion gt jEngine oil change 25H 1M 250 400 Break in oil and filter change see page 47 gt Demand drive fluid 25 H 1M 250 400 Change fluid every 25 hours extreme use if ADC is subjected to extreme use See page 87 gt Demand drive fluid 25 H 1M 250 400 Break in oil level check gt Rear gearcase oil 25H 1M 250 400 Break in oil level check gt Transmission oil 25H 1M 250 400 Break in oil level check gt General lubrication 50H 3M 500 800 Lubricate all fittings pivots cables etc Shift linkage 50 H 6M 500 800 Inspect lubricate D Steering 50 H 6M 500 800 Lubricate gt Front suspension 50 H 6M 500 800 Lubricate gt Rear suspension 50H 6M 500 800 Lubricate D Throttle Cable 50 H 6M 500 800 Inspect adjust lubricate E Throttle Release replace if necessary Switch E Throttle Body 50 H 6M 500 800 Inspect duct for proper Intake Duct sealing air leaks Drive belt 50 H 6M 500 800 Inspect replace as needed Cooling system 50 H 6M 1000 1600 Inspect coolant strength seasonally pressure test system yearly gt Radiator 50 H 6M 1000 1600 Inspect clean external surfaces gt Cooling hoses 50 H 6M 1000 1600 Inspect for leaks b Oil lines fasteners 50H 6M 1000 1600 Inspect for leaks and loose
32. CAPACITY of the vehicle When determining the weight you are adding to the vehicle include the weight of the operator accessories loads in the rack or box and the load on the trailer tongue The combined weight of these items must not exceed the maximum weight capacity CARGO WEIGHT DISTRIBUTION should be 1 3 on the front rack and 2 3 on the rear rack When operating over rough or hilly terrain reduce speed and cargo to maintain stable driving conditions Carrying loads on only one rack increases the possibility of vehicle overturn CARRY LOADS AS LOW ON THE RACKS AS POSSIBLE Carrying loads high on the racks raises the center of gravity of the vehicle and creates a less stable operating condition SECURE ALL LOADS BEFORE OPERATING Unsecured loads can create unstable operating conditions which could result in loss of control of the vehicle OPERATE ONLY WITH STABLE AND SAFELY ARRANGED LOADS When handling off centered loads that cannot be centered securely fasten the load and operate with extra caution Always attach the tow load to the hitch point designated for your vehicle HEAVY LOADS CAN CAUSE BRAKING AND CONTROL PROBLEMS Use extreme caution when applying brakes with a loaded vehicle Avoid terrain or situations that may require backing downhill USE EXTREME CAUTION when operating with loads that extend over the rack sides Stability and maneuverability may be adversely affected causing the vehicle to overturn DO NOT BLOCK THE FRON
33. 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 e Avoid the use of harsh cleaners which can scratch the finish e Do not use a power washer to clean the vehicle e Do not use medium to heavy duty compounds on the finish e 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 MAINTENANCE Cleaning and Storage Washing the Vehicle If a high pressure water system is used for cleaning not recommended exercise extreme caution The water mav damage components and could remove paint and labels Avoid directing the water stream at the following items e Wheel bearings e Electrical components e Radiator e Switches and controls e Transmission seals e Fuel system components e Cab and body panels e Labels and decals If an informational or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge Grease all zerk fi
34. Digital Analog Gauge Rider Information Center Engine Error Codes The error screen displays only when the CHECK ENGINE light is on or when it goes on and off during one ignition cycle Error codes are not stored in the gauge when the key is turned off The code and message is lost but will reappear if the fault reoccurs after restarting the engine If the CHECK ENGINE light illuminates retrieve the error codes from the display Please see your Suspect Parameter Number SPN Error Code Number 0 9 Failure Mode Indicator FMI Polaris dealer for all major repairs 1 Ifthe error codes are not displayed use the MODE button to toggle until Ck ENG displays on the main line of the display 2 Press and hold the MODE button to enter the diagnostics code menu 3 Record the numbers displayed in the gear position if any clock and odometer displays 4 Press the MODE button to advance to the next error code a Press and hold the MODE button to exit the diagnostics code menu 6 See pages 42 45 for code definitions and failure descriptions Please see your Polaris dealer for all major repairs 41 FEATURES AND CONTROLS Instrument Cluster Diagnostic Displav 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
35. E 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 In the Country where your product 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 product was purchased Warranty and Service Bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product Outside the Country where your product was purchased If you are traveling temporarily outside the country where your product was purchased you should take your product 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 perform 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 Product importation rules vary considerably from country to country You may be required to present documentation of your move to POLARIS in order to continue your warranty coverage You may also be required to obtain documentation from POLARIS in order to register your product in your new country You should w
36. H OF THIS WARRANTY SHALL BE AT POLARIS OPTION REPAIR OR REPLACEMENT OF ANY DEFECTIVE MATERIALS COMPONENTS OR PRODUCTS THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE THE IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE IS EXCLUDED FROM THIS LIMITED WARRANTY ALL OTHER IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTY OF MERCHANTABILITY ARE LIMITED IN DURATION TO THE ABOVE SIX MONTH WARRANTY PERIOD POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS WARRANTY SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES OR ALLOW LIMITATIONS ON THE DURATION OF IMPLIED WARRANTIES SO THE ABOVE LIMITATIONS MAY NOT APPLY TO YOU IF INCONSISTENT WITH CONTROLLING STATE LAW 135 WARRANTV How To Obtain Warrantv Service If your vehicle requires warranty service you must take it to a POLARIS Servicing Dealer When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer TH
37. IS Initial dealer preparation and set up of your vehicle 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 Warranty Coverage And Exclusions Limitations Of Warranties And Remedies This POLARIS limited warranty excludes any failures that are not caused by a defect in material or workmanship THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN This warranty also does not cover acts of God accidental damage normal wear and tear abuse or improper handling This warranty also does not cover any vehicle component or part that has been altered structurally modified neglected improperly maintained or used for racing competition or purposes other than for which it was designed This warranty excludes damages or failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation snow water dirt or other foreign substance ingestion contamination improper maintenance modified components use of aftermarket or unapproved components accessories or attachments unauthorized repairs or repairs made after the warranty period expires or by an unauthorized repair center 134 WARRANTV Warrantv Coverage And Exclusions Limitations Of Warranties
38. IS Industries Inc 2100 Highway 55 Medina MN 55340 POLARIS gives a SIX MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship POLARIS further warrants that the spark arrester in this product will meet the efficiency requirements of USFS standard 5100 1C for at least 1000 hours when subjected to normal use and when maintenance and installation are in accordance with POLARIS recommendations This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase by the original retail purchaser This warranty is transferable to another owner during the warranty period through a POLARIS dealer but any such transfer will not extend the original term of the warranty The duration of this warranty may vary by international region based upon local laws and regulations Registration At the time of sale the Warranty Registration Form must be completed by your dealer and submitted to POLARIS within ten days of purchase 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 your proof of warranty coverage If you have not signed the original registration and received the customer copy please contact your dealer immediately NO WARRANTY COVERAGE WILL BE ALLOWED UNLESS YOUR VEHICLE IS REGISTERED WITH POLAR
39. ND CONTROLS Electronic Power Steering EPS Electronic power steering EPS engages when the ignition key is turned to the ON position EPS remains engaged whether the vehicle is moving or idle See page 35 for EPS Warning Indicator information Fuel Tank Always refuel with the engine stopped and outdoors or in a well ventilated area Refuel on a level surface Remove the fuel tank cap and add fuel Use either leaded or unleaded gasoline with a minimum pump octane number of 87 R M 2 octane Do not use fuel with ethanol content greater than 10 such as E 85 fuel The fuel tank is designed to allow for the normal expansion of fuel Do not overfill Do not fill the tank neck Extreme Use Batterv An optional extreme use batterv mav be available for vour model If the performance of the factory installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories please see your POLARIS dealer Ask your dealer to provide any installation procedures that may differ for an extreme use battery 31 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 33 4X4 Mode When the swit
40. OR OTHER TORT OR OTHERWISE THIS EXCLUSION OF CONSEQUENTIAL INCIDENTAL AND SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE ALL IMPLIED WARRANTIES INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN POLARIS DISCLAIMS ALL EXPRESS WARRANTIES 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 inconsistent with the controlling state law 139 WARRANTV U S A EPA Emissions Limited Warrantv This limited warrantv excludes failures not caused bv a defect in material or workmanship This limited warrantv does not cover damage due to accidents abuse or improper handling maintenance or use This limited warrantv also does not cover anv engine that has been structurallv altered or when the vehicle has been used in racing competition This limited warrantv also does not cover phvsical damage corrosion or defects caused by fire explosions or other similar causes beyond the control of POLARIS Owners are responsible for performing the scheduled maintenance identified in the owner s manual POLARIS may deny warranty claims for failures that have been caused by the owner s or operator s improper maintenance or use by accidents for which POLARIS has no respo
41. Reinstall the front rack Fuse Box 100 MAINTENANCE Lights Poor lighting can result in reduced visibilitv when driving Headlight and taillight lenses become dirtv during normal operation Clean lights frequently and replace burned out lamps 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 fingers 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 five 5 headlight pod screws 2 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 3 Unplug the headlamp from the wiring harness Be sure to pull on the connector not on the wiring 4 Turn the lamp counter clockwise to remove it 5 Install the new lamp Make sure the tab on the lamp locates properly in the housing 6 Reassemble the pod 101 MAINTENANCE Lights High Beam Adjustment The headlight beam can be adjusted slightly upward or downward Use the following procedure to make the adjustment 1 Position the vehicle on a level surface with the headlight approximately 25 ft 7 6 m from a wall Place the transmission in PARK 25 ft 7 6 m Lamp Center Height 2 5 cm
42. Sportsman 850 Sportsman 850 SP Sportsman XP 1000 Owner s Manual for Maintenance and Safety Read this manual carefully It contains important safety information This is an adult vehicle only Operation is prohibited for those under 16 years of age A 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 safetv 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 a dri m m For videos and more information about a safe riding experience with your Polaris vehicle scan this QR code with your smartphone WELCOME Thank vou for purchasing a POLARIS vehicle and welcome to our world wide family of POLARIS enthusiasts Be sure to visit us online at www polaris com for the latest news new product introductions upcoming events career opportunities and more Here at POLARIS we proudly produce an exciting line of utility and recreational products e Snowmobiles e All terrain vehicles ATVs e Low emission vehicles LEVs e RANGER utility vehicles e RZR sport vehicles e VICTORY motorcycles e GEM electric vehicles We believe POLARIS sets a standard of excellence for all utility and recreational vehicles manufactured in the world to
43. T HEADLIGHT BEAM when carrying loads on the front rack DO NOT TRAVEL FASTER THAN THE RECOMMENDED SPEEDS NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 Ibs 91 kg and or front cargo loads are above 100 Ibs 45 kg Vehicle should never exceed 10 MPH 16 km h while towing a load on a level surface Vehicle speed should never exceed 5 MPH 8 km h when towing loads in rough terrain while cornering or while ascending or descending a hill 62 Hauling Cargo 1 Never exceed the weight capacities specified for vour ATV on warning labels and in the specifications section of this manual Cargo weight should be evenly distributed 1 3 on the front rack and 2 3 on the rear rack and mounted as low as possible When operating over rough or hilly terrain reduce speed and cargo weight to maintain stable driving conditions OPERATION NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 Ibs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 Ibs 91 kg and or front cargo loads are above 100 Ibs 45 kg Do not obstruct the headlight beam with cargo Use low forward gear when hauling or towing heavy cargo to extend belt life 63 OPERATION Hauling Cargo Towing Loads Alwav
44. a Look ahead and learn to read the terrain Be constantly alert for hazards such as logs rocks and low hanging branches Travel slowly and use extra caution when operating on unfamiliar terrain Not all obstacles are immediately visible Never attempt to operate over large obstacles such as rocks or fallen trees OPERATION Driving in Reverse Follow these precautions when operating in reverse TEO AA e p n Always check for obstacles or people behind the vehicle Always avoid backing downhill Back slowly Apply the brakes lightly for stopping Avoid turning at sharp angles Never open the throttle suddenly Do not use the override button unless additional wheel speed is required for vehicle movement Use the override with caution as rearward vehicle speed is greatly increased Do not operate at wide open throttle Operate the throttle just enough to maintain a desired speed NOTICE Excessive throttle operation while in the speed limit mode may cause fuel to build in the exhaust resulting in engine popping and or engine damage 61 OPERATION Hauling Cargo A WARNING Overloading the vehicle or carrving or towing cargo improperlv can alter vehicle handling and mav cause loss of control or brake instabilitv which can result in serious injurv or death Alwavs follow these precautions when hauling cargo REDUCE SPEED AND ALLOW GREATER DISTANCES FOR BRAKING WHEN HAULING CARGO NEVER EXCEED THE MAXIMUM WEIGHT
45. able before each use Never winch the hook fully into the winch This can cause damage to winch components Unplug the remote control from the vehicle when the winch is not in use to prevent inadvertent activation and use by unauthorized persons Never grease or oil the winch cable This will cause the winch cable to collect debris that will shorten the life of the cable 67 WINCH GUIDE Winch Operation Read the Winch Safetv Precautions in the preceding pages before using your winch Tip Consider practicing the operation and use of your winch before you actually need to use it in the field A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Each winching situation is unique Take your time to think through the winching you are about to do Proceed slowly and deliberately Never hurry or rush during winching Always pay attention to your surroundings You may need to change your winching strategy if it is not working Always remember that your winch is very powerful There are simply some situations that you and your winch will not be able to deal with Do not be afraid to ask others to help when this happens 1 Always inspect the vehicle winch winch cable and winch controls for any signs of damage or parts in need of repair or replacement before each use Pay particular attention to the first 3 feet 1 meter of winch cable if the win
46. aged It can no longer transmit the load that it could prior to kinking Promptly discontinue use of a winch cable in this condition C A winch cable made of synthetic rope should be inspected for signs of fraying Replace the cable if fraying is observed shown at right 4 oe h C Promptly discontinue use of a winch cable in this condition D Also replace the winch cable if there are fused or melted fibers Such an area of the synthetic rope will be stiff and appear smooth or glazed Promptly discontinue use of a winch cable in this condition 73 WINCH GUIDE Shock Loading WARNING Your winch cable is very strong but it is NOT designed for dynamic or shock loading Shock loading may tension a winch cable beyond its strength and cause the cable to break The end of a broken winch cable under such high loading can cause SEVERE INJURY or DEATH to you and other bystanders Winch cables are designed to NOT absorb energy This is true of both wire rope and synthetic rope winch cables 1 Never attempt to jerk a load with the winch For example never take up slack in the winch cable by moving the winching vehicle in an attempt to move an object This is a dangerous practice It gener ates high winch cable loads that may exceed the strength of the cable Even a slowly moving vehicle can create large shock loads in a winch cable WARNING SEVERE INJURY or DEATH can result from a broken winch cable 2 74 Never
47. an help as a damper if no other items are available to you Lay the damper on top of the mid point of the winch cable length that is spooled out On a long pull it may be necessary to stop winching so that the damper can be repositioned to the new mid point of the winch cable Always release the tension on the winch cable before repositioning the damper Avoid being directly in line with the winch cable whenever possible Also never permit others to stand near or in line with the winch cable during winch operation Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure Never use straps chains or other rigging items that are damaged or worn WINCH GUIDE Winch Operation 11 The ONLY time a winch equipped vehicle should be moving when using the winch is when that vehicle itself is stuck The winch equipped vehicle should NEVER be in motion to shock load the winch cable in an attempt to move a second stuck vehicle See the Shock Loading section on page 74 For vour safetv alwavs follow these guidelines when winching a vehicle free 12 IO J K mmo O p p Release the winch clutch and spool out the necessary length of winch cable Align the winch cable as close as possible to the winching vehicle s centerline Attach the winch cable hook to the anchor point or the stuck vehicle s frame following instructions in this manual Re engage the clutch
48. 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 internallv Short to Batterv The wire leading from the item listed in the chart to the electronic control unit is shorted to a wire at batterv voltage Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 51 4 Engine Temperature Sensor Voltage Too High 110 3 Voltage Too Low 110 4 Temperature Too High 110 16 Engine Overheat Shutdown 110 0 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 105 4 Manifold Absolute Pressure Sensor Voltage Too High 102 3 Voltage Too Low 102 4 Signal Out of Range 102 2 Crankshaft Position Sensor Circuit Fault 636 8 Plausibility Fault 636 2 Vehicle Speed Signal Speed Too High 84 8 Plausibility Fault 84 2 Gear Sensor Signal Voltage Too Low 523 4 Voltage too high 523 3 Signal fault 523 2 Injector 1 MAG SDI Part Load Driver Circuit Open Grounded 651 5 Driver Circuit Short to B 651 3 Driver Circuit Grounded 651 4 Injector 2 PTO SDI Part Load Driver Circuit Open Grounded 652 5 Driver Circuit Short to B 652 3 Driver Circuit Grounded 652 4 42 FEATURES AND CONTROLS Instrument Cluster Diagnostic Displav Code Definitions Diagnostic Codes
49. arranty register your product at a local POLARIS dealer in your new country immediately after you move to continue your warranty coverage and to ensure that you receive information and notices regarding your vehicle If you purchase from a private party If you purchase a POLARIS product from a private party to be kept and used outside of the country in which the product was originally purchased all warranty coverage will be denied You must nonetheless register your product under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your product Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER S AUTHORIZED LOCATION This policy does not apply to products that have received authorization for export from POLARIS Dealers may not give authorization for export You should consult an authorized dealer to determine this product s warranty or service coverage if you have any questions This policy does not apply to products registered to government officials or military personnel on assignment outside the country of the selling dealer s authorized location This policy does not apply to Safety Bulletins 136 WARRANTV Notice If your product is registered outside of the country where it was purchased and you have not followed the p
50. ate 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 Always operate at a speed that s appropriate for the terrain the visibility and operating conditions and your experience 12 SAFETV Safetv Warnings Phvsical Control of the ATV Removing a hand from the handlebars or feet from the footrests during operation can reduce vour abilitv to control the vehicle or cause loss of balance and ejection from the ATV If the operator s foot is not firmly planted on the footrest it could also contact the rear wheels Never remove your hands from the handlebars while operating and always keep both feet on the footrests Turning Improperly Turning improperly could cause loss of traction loss of control accident or overturn Always follow proper procedures for turning as described in the owner s manual Never turn abruptly or at sharp angles Never turn at high speeds Practice turning at slow speeds before attempting to turn at faster speeds Jumps and Stunts Attempting wheelies jumps and other stunts increases the risk of an accident or overturn Never attempt wheelies jumps or other stunts Avoid exhibition driving Improper Hill Climbing Improper hill climbing could cause loss of control or overturn Always follow proper procedures for climbing hills as described in the owner s manual Se
51. ch before each use Inspect for worn or kinked winch cable Also inspect for worn or loose parts including mounting hardware Permit your winch motor to cool down prior to servicing your winch Never work on your winch without first disconnecting the battery connections to prevent accidental activation of the winch For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer Some winch models use wire rope as the winch cable Other winches use a specially designed synthetic rope as the winch cable Never replace a synthetic rope winch cable with a consumer grade polymer rope such as can be purchased in a hardware store Although they may look similar they are NOT alike A polymer rope not designed for winch use will stretch and store excessive energy when winching WARNING Failure of a stretched rope under winching conditions will release all of the stored energy This will increase the chances of SEVERE INJURY or DEATH 76 EMISSION CONTROL SVSTEMS Noise Emission Control Svstem Do not modifv the engine intake or exhaust components as doing so may affect compliance with U S A EPA noise control requirements 40 CFR 205 and local noise level requirements Operation on Public Lands in the U S A Your POLARIS vehicle has a spark arrester that was tested and qualified to be in accordance with the USFS standard 5100 1c Federal law
52. ch is being used or has been used for lift ing an accessory plow assembly Promptly replace any worn or damaged cable 2 Never operate a winch or a vehicle in need of repair or service 3 Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 68 Hook Strap A AP Ca WINCH GUIDE Winch Operation 4 Always use the hook strap when handling the hook WARNING Never put your fingers into the hook This could lead to SEVERE INJURY A Attach the hook itself onto the load or use a tow strap or chain NO YES to secure the load to the winch cable Tip A tow strap is NOT intended to stretch A recovery strap is designed to stretch WARNING Never use a recovery strap when winching due to the excessive energy that can be released if the winch cable breaks This can result in SEVERE INJURY or DEATH See the Shock Loading section on page 74 B Never hook the winch cable back onto itself This will damage the winch cable and may result in winch cable failure WARNING Replace the winch cable at the first sign of damage to prevent SEVERE INJURY or DEATH in the event of failure For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer C If possible keep the winch cable aligned with the centerline of the winching vehicle This w
53. ch is on 4X4 the ATV is in 4X4 and the 4X4 indicator icon in the instrument cluster display will be visible When in 4X4 the demand drive unit will automatically engage any time the rear wheels lose traction When the rear wheels regain traction the demand drive unit will automatically disengage There is no limit to the length of time the vehicle may remain in 4X4 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position 2X4 Mode When the switch is on 2X4 the ATV is in two wheel drive at all times 32 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 Active Descent Control ADC System The ADC system allows engine braki
54. ctions for this vehicle are in English Other languages are provided as translations of the original instructions Printed in U S A 2015 SPORTSMAN 850 SPORTSMAN 850 SP SPORTSMAN XP 1000 Owner s Manual P N 9925442 TABLE OF CONTENTS Introduction sssssssszznszjjjdnmpiostezi 4 DANGLY ii ied on Bini im B eae Be Ko 7 Features and Controls 24 Operation 2ccistnccattuseucseseceaeee es 47 Winch Guide s isspen ifzonznettistes est 65 Emission Control Systems 77 Maintenance 2222200eeeeees 78 Troubleshooting en 125 POLARIS Products sess 129 Specifications 2000eeeeennees 130 Warranty o c lt t se coceme see ckw ey rena wees 134 Maintenance Log 2 2 055 141 INGEX 226 25 cseaueeesseuices EE 144 INTRODUCTION The following signal words and svmbols appear throughout this manual and on vour vehicle Xour safetv is involved when these words and svm bols are used Become familiar with their meanings before reading the manual A The safety alert symbol indicates a potential personal injury hazard DANGER A DANGER indicates a hazardous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A
55. d as indicated by the test procedure s The uncertainty of vibration exposure measurement is dependent on many factors including e Instrument and calibration uncertainty e Variations in the machine such as wear of components e Variation of machine operators such as experience or physique e Ability of the worker to reproduce typical work during measurements e Environmental factors such as ambient noise or temperature 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 The manufacturer s label is located on the front right side of the vehicle behind the radiator Engine Serial Number HHHH Key Bali Are Manufacturer s Label Number Vehicle Model Number Frame VIN Engine Serial Number Key Number SAFETV Safetv Training ATV safety training is a top priority for POLARIS POLARIS strongly encourages you and any family members who will be riding the ATV to take a training course If you purchased a new POLARIS ATV in the United States your dealer provided information about the authorized ATV RiderCourse
56. d fuel Clogged fuel filter See vour dealer Incorrect fuel Replace with recommended fuel Possible Rich Fuel Cause Solution Fuel is verv high octane Replace with lower octane fuel Stopping starting without adequate Allow engine to warm up before operat warm up ing and or stopping Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace 127 TROUBLESHOOTING Engine Stops or Loses Power Possible Cause Out of fuel Solution Refuel cycle key to ON position three times for 5 seconds each then start Kinked or plugged fuel vent line Inspect and replace Water is present in fuel Replace with new fuel Fouled or defective spark plugs Inspect clean and or replace spark plug Worn or defective spark plug wires See your dealer Incorrect spark plug gap or heat range Set gap to specs or replace plug Loose ignition connections Check all connections and tighten Low battery voltage Recharge the battery to 12 8 VDC Incorrect fuel Replace with fresh recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See your dealer Electronic throttle control malfunction See your dealer Other mechanical failure See your dealer Overheated engine Clean radiator screen and core clean engine exterior see your dealer Engine Overheating Possible Cause Solution
57. d out the winch cable that is unevenly bunched up in one area Re engage the winch clutch Have an assistant pull the winch cable tightly with about 100 Ibs 45 kg of tension using the hook strap Slowly winch the cable in while your assistant moves the end of the winch cable back and forth horizontally to evenly distribute the winch cable on the drum F Doing this reduces the chances of the winch cable wedging itself between lower layers of winch cable m Jop 12 WINCH GUIDE Winch Cable Care For your safety always replace POLARIS winch parts including the cable with genuine POLARIS replacement parts available at your authorized POLARIS dealer WARNING Use of worn or damaged cable could lead to sudden failure and SEVERE INJURY 1 Always inspect your winch before each use Inspect for worn or loose parts including mounting hardware Never use the winch if any part needs repair or replacement 2 Always inspect your winch cable before each use Inspect for worn or kinked winch cable A A kinked winch cable made of wire rope is shown at right Even after being straightened out this cable has already been permanently and severely damaged Promptly discontinue use of a winch cable in this condition B Akinked winch cable made of wire rope that has been ec FCO SR IO TITTLE straightened out is shown at B right Even though it may look usable the cable has been permanently and severely dam
58. day Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master Service Dealer MSD technician Your POLARIS dealer knows your vehicle best and is interested in your total satisfaction Be sure to return to your dealership for all of your service needs during and after the warranty period POLARIS POLARIS SPORTSMAN and SPORTSMAN XP are trademarks of POLARIS Industries Inc Copyright 2014 POLARIS Industries Inc All information contained within this publication is based on the latest product information at the time of publication Due to constant improvements in the design and quality of production components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instru
59. e The term winch cable will be used for either unless noted otherwise Winch Safety Precautions a oa ie 10 Read all sections of this manual Never use alcohol or drugs before or while operating the winch Never allow children under 16 years of age to operate the winch Always wear eye protection and heavy gloves when operating the winch Always keep body hair clothing and jewelry clear of the winch cable fairlead and hook when operating winch Never attempt to jerk a load attached to the winch with a moving vehicle See the Shock Loading section on page 74 Always keep the area around the vehicle winch winch cable and load clear of people especially children and distractions while operating the winch Always turn the vehicle ignition power OFF when it and the winch are not being used Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Always apply your vehicle s park brake and or park mechanism to hold the vehicle in place during winching Use wheel chocks if needed 65 WINCH GUIDE Winch Safetv Precautions 11 Always align the vehicle and winch with the load directly in front of the vehicle as much as possible Avoid winching with the winch cable at an angle to the winching vehicle s centerline whenever possible 12 If winch
60. e failure to conduct this maintenance will not void the emissions warranty but may affect emissions D Have an authorized POLARIS dealer perform these services WARNING Improperly performing the procedures marked with a D could result in component failure and lead to serious injury or death Have an authorized POLARIS dealer perform these services Perform all services at whichever maintenance interval is reached first Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km Steering Front suspension Rear suspension Tires Brake fluid level Pre Ride See Pre Ride Checklist on Brake lever travel page 48 Brake system Wheels fasteners Frame fasteners Engine oil level 7 gt Air filter pre filter Daily Inspect clean often replace E as needed Coolant Daily Check level gt Power steering unit Daily 2 Inspect daily clean often if equipped Headlamp taillight Daily Check operation 79 MAINTENANCE Periodic Maintenance Chart Item Maintenance Interval Remarks whichever comes first Hours Calendar Miles Km gt Air filter main Weekly Inspect replace as needed E element b Brake pad wear 10H Monthly 100 160 Inspect periodically
61. e page 55 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill 13 SAFETV Safetv Warnings Descending Hills Improperly Improperly descending a hill could cause loss of control or overturn e Always follow proper procedures for traveling down hills as described in the owner s manual NOTE A special technique is required when braking while traveling downhill See page 57 e Always descend a hill with the transmission in forward gear Do not descend a hill with the transmission in neutral Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 e Always check the terrain carefully before descending a hill e Shift your weight rearward e Never travel down a hill at high speed e Avoid traveling down a hill at an angle which would cause the vehicle to lean sharply to one side Travel straight down the hill when possible Crossing Hillsides Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a hillside is unavoidable always follow proper procedures as described in the owner s manual See page 56 Never attempt to turn the ATV around on any hill until you ve mastered the turning technique on level ground as described in the owner s manual See page 58 14 SAFETV Safetv Warnings Stalling While Climbing a Hill Stalli
62. e spark plug cap 1 4 turn and pull it off the spark plug 2 Rotate the spark plug counter clockwise to remove it 3 Reverse the procedure for spark plug installation Torque to specification 106 MAINTENANCE Spark Plugs Spark Plug Inspection Normal Spark Plug The normal insulator tip is grav tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper tvpe and heat range for the engine and the service The tip should not be flakv and white A white insulator tip indicates overheating caused bv 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 MAINTENANCE Vehicle Immersion If vour vehicle becomes immersed major engine damage can result if the machine is not thoroughiv inspected Take the vehicle to vour 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 il the filter with a new filter If mary E a equipped remove t
63. eed is not satisfactory please see your POLARIS dealer for adjustment Throttle Cable Freeplay 1 Remove the four cover screws from the right handlebar control and remove the cover 2 With the handlebars straight ahead place very light pressure on the throttle lever A gap of 2 3 mm should be visible between the throttle arm stop pin and the throttle arm Arm Stop Pin If adjustment is needed 1 Locate the throttle cable adjuster Squeeze the end of the rubber boot and slide it back far enough to expose the inline cable adjuster locknut 2 Loosen the adjuster locknut 3 Rotate the boot to turn the adjuster until 2 3 mm of freeplay is achieved between the stop pin and the throttle arm While Boot adjusting freeplay flip the throttle lever back and forth repeatedly Cable Adjuster continued on next page Lock Nut Adjuster 114 MAINTENANCE Throttle Cable Freeplav 4 5 6 10 Place the transmission in PARK Lock the parking brake Start the engine and allow the idle to stabilize If necessary tap the throttle lever to ensure the idle speed settles If idle speed remains above or below the recommended setting see specification pages verify the correct gap If gap is correct and idle speed is still not satisfactory please see your POLARIS dealer for service With the engine running turn the handlebars fully to the left and right Tap the throttle lever at each turn v
64. erifying that idle RPM returns to the recommended setting If idle speed increases it may be necessary to increase the gap between the stop pin and throttle arm but do not exceed the recommended 2 3 mm gap When adjustments are complete tighten the locknut Squeeze the end of the rubber boot and slide it over the cable adjuster to its original position Ensure the control cover seal is in place then reinstall the cover and screws 115 MAINTENANCE Batterv A 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 Your ATV is equipped with a sealed battery which requires little maintenance POLARIS does not recommend using a conventional battery in this vehicle The orientation of the battery could result in electrolyte leakage which would shorten the life of the battery considerably 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 terminals with dielectric grease or petroleum jelly Battery Removal 1 Remove the front rack Disconnect the black negative battery cable first Di
65. erious injury or death Read and understand all safety warnings outlined in the safety section of this owner s manual Break In Period The break in period for your new POLARIS ATV is the first 20 hours of operation No single action on your part is as important as following the procedures for a proper break in Careful treatment of a new engine and drive components will result in more efficient performance and longer life for these components NOTICE Excessive heat build up during the first three hours of operation will damage close fitted engine parts and drive components Do not operate at full throttle or high speeds during the first three hours of use Engine and Drivetrain Break in 1 Fill the fuel tank with gasoline See page 31 Always exercise extreme caution whenever handling gasoline 2 Check the engine oil level on the dipstick See page 83 Add oil if necessary to maintain the level between the safe and add marks 3 Drive slowly at first Select an open area that allows room to familiarize yourself with vehicle operation and handling 4 Vary the throttle positions Do not operate at sustained idle 5 Perform regular checks on fluid levels controls and areas outlined on the daily pre ride inspection checklist See page 48 6 Pull only light loads Change both the oil and the filter at 25 hours Check fluid levels of transmission and all gearcases after the first 25 hours of operation and every 100 hours therea
66. ery voltage with a voltmeter or multimeter A fully charged battery will register 12 8 V or higher 2 Ifthe 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 manufacturer s instructions for recharging When using a constant current charger use the guidelines on the next page for recharging 118 MAINTENANCE Batterv Batterv Charging Always verify battery condition before and 1 2 hours after the end of charging Charge Time State of f g Voltage Action Using constant current Charge charger standard amps specified on top of battery 100 12 8 13 0 volts None check at 3 None required mos from date of manufacture 75 100 12 5 12 8 volts May need slight 3 6 hours charge if no charge given check in 3 months Needs charge 5 11 hours 50 75 12 0 12 5 volts 25 50 11 5 12 0 volts Needs charge At least 13 hours verify state of charge 0 25 11 5 volts or less Needs charge with desulfating charger At least 20 hours 119 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
67. evel 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 28 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 03 0 762 mm 5 Check the security and surface condition 03 0 762 mm of the disc Clean any grease using a recommended brake cleaner or alcohol Do not use spray lubricants or other petroleum based products If you discover any damage cracks excessive corrosion warping see your dealer for service before operating Auxiliary Foot Brake The hydraulic auxiliary brake system requires no adjustment Check the brake fluid level frequently for the auxiliary brake system See page 30 93 MAINTENANCE Toe Alignment Use the following procedure to check the toe alignment of the vehicle The recommended toe alignment is 1 4 1 2 inch 6 12 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 Ye 2 Place the handlebars ina Stand l straight ahead position l 3 Tie a le
68. f 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 oy 57 OPERATION Turning Around on a Hill K Turn If the vehicle stalls while climbing a hill never back it down the hilll Use the K turn to turn around 58 Stop and lock the parking brake while keeping body weight uphill Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 Leave the transmission in forward and shut off the engine Dismount on the uphill side of the vehicle or on the left if the vehicle is pointing straight uphill Staying uphill of the vehicle turn the handlebars full left While holding the service brake release the parking brake lock and slowly allow the vehicle to roll around to your right until it s pointing across the hill or slightly downward Lock the parking brake and remount the vehicle from the uphill side keeping body weight uphill Restart the engine with the transmission still in forward Release the parking brake and proceed slowly controlling speed with the service brake until the vehicle is on more level ground OPERATION Driving Through Water Your ATV can operate through water with a maximum recommended depth equal to the bottom of the footrests Follow these precautions when operating through water 1 Determine water depths and cur
69. filter sealing surface on the crankcase 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 Install the new filter and rotate it clockwise bv hand until the filter Oil Filter gasket contacts the sealing surface then turn it an additional 1 2 turn Remove the dipstick Add the proper amount of the recommended oil Do not overfill Reinstall the dipstick XP 1000 only Reinstall the guard plate over the oil filter access Place the transmission in PARK Lock the parking brake Start the engine Allow it to idle for one to two minutes Stop the engine Check for leaks Check the oil level Add oil as needed to bring the level to the upper mark on the dipstick Dispose of used filter and oil properly 85 MAINTENANCE Transmission Oil POLARIS recommends the use of POLARIS AGL Gearcase Lubricant amp Transmission Fluid for this transmission See the table on page 82 for fluid recommendations capacities and plug torques Always check and change the transmission oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 See page 129 for the part numbers of POLARIS products Maintain the oil level at the bottom of the fill plug hole The fill plug is located on the right side of the ATV behind the footwell The drain plug is located on the bottom rear of the gearcase Oil Check 1 Remove the footwell see page 9
70. freezing Wrong or missing belt Install the recommended belt Improper break in Always break in a new belt and or clutch See page 47 125 TROUBLESHOOTING Engine Doesn t Turn Over Possible Cause Low batterv voltage Solution Recharge the batterv to 12 8 VDC Loose batterv connections Check all connections and tighten Loose solenoid connections Check all connections and tighten 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 See your dealer Water is present in fuel Drain the fuel system and refuel Old or non recommended fuel Replace with fresh recommended fuel Fouled or defective spark plugs Inspect plugs and replace if necessary No spark to spark plug Inspect plugs verify stop switch is on Water or fuel in crankcase Immediately see your POLARIS dealer Low battery voltage Recharge the battery to 12 8 VDC Mechanical failure See your dealer Engine Backfires Possible Cause Weak spark from spark plug Solution Inspect clean and or replace spark plugs Incorrect spark plug gap or heat range Set gap to specs or replace plugs Old or non recommended fuel Replace with fresh recommended fuel Incorrectly installed spark plug wires See your dealer Incorrect ignition ti
71. fter PVT Break in Clutches Belt A proper break in of the clutches and drive belt will ensure a longer life and better performance Break in the clutches and belt by operating at slower speeds during the break in period as recommended Pull only light loads Avoid aggressive acceleration and high speed operation during the break in period If a belt fails always clean away all debris when replacing the belt 47 OPERATION Pre Ride Checklist Failure to inspect and verifv that the ATV is in safe operating condition before operating increases the risk of an accident Alwavs inspect the ATV before each use to make sure it s in safe operating condition Item Remarks Page Brake svstem lever travel Ensure proper operation A Brake fluid Ensure proper level 28 Auxiliary brake Ensure proper operation 30 Front suspension Inspect lubricate if necessary 82 Rear suspension Inspect lubricate if necessary 82 Steering Ensure free operation z Tires Inspect condition and pressure 96 Wheels fasteners Inspect ensure fastener tightness ee Frame nuts bolts fasteners Inspect ensure tightness l Fuel and oil Ensure proper levels a Coolant level Ensure proper level a Coolant hoses Inspect for leaks Throttle Ensure proper operation o Indicator lights switches Ensure operation 24 Engine stop switch Ensure proper operation 25 Air filter pre filter Inspect clean 99 Headlamp Chec
72. g Procedures b e oF Soy See a 52 Wear a helmet and eye protection Sit upright with both feet on the footrests and both hands on the handlebars Start the engine and allow it to warm up Shift the transmission into gear Check your surroundings and determine your path of travel Release the parking brake Slowly depress the throttle with your right thumb and begin driving Drive slowly Practice maneuvering and using the throttle and brakes on level surfaces OPERATION Turning the Vehicle Your ATV is equipped with a h solid rear axle which drives both rear wheels equally at all times This means that the wheel on the outside of the turn must travel a greater distance than the inside wheel when turning and the inside tire must slip traction slightly To turn steer in the direction of the turn leaning your upper body to the inside of the turn while supporting your weight on the outer footrest This technique alters the balance of traction between the rear wheels allowing the turn to be made smoothly The same leaning technique should be NS used for turning in reverse Practice making turns at slow speeds before attempting to turn at faster speeds WARNING Turning improperly can result in vehicle overturn Never turn abruptly or at sharp angles Never turn at high speeds 53 OPERATION Driving on Slipperv Surfaces Sideway Turn in Skid direction of C IEC COSC RA N
73. 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 temperature inside the clutch cover greatly extends the life of the PVT components belt cover etc 111 MAINTENANCE PVT Svstem When To Use Low Range and High Range Condition Range to Use Operating at speeds less than 7 MPH 11 km h Low Towing heavv loads Low Operating in rough terrain swamps mountains etc Low Operating at speeds greater than 7 MPH 11 km h High PVT Drving There mav be some instances when water is accidentiv ingested into the PVT svstem Use the following instructions to drv it out before operating 1 Position the vehicle on a level surface 2 Remove the drain plug Allow the water to drain completely Reinstall 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 5 seconds 5 Allow the engine RPM to settle to idle speed then shift the tran
74. he air box drain A plug to drain water Make sure the kat k E ring is on the drain plug and yet ak Seema reinstall the drain plug a Il l pri NOTICE Serious damage could occur if eda yp l the air box drain plug is not fi aN ee f reinstalled and tightened E l properly SA Ferrare JESS 3 Remove the spark plugs Drain Plug 4 Turn the engine over several times using the electric start 5 Dry the spark plugs Reinstall the plugs or install new plugs 6 Attempt to start the engine If necessary repeat the drying procedure NOTICE Serious damage can occur after immersion if fluids are not changed promptly See your dealer as recommended 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 MAINTENANCE Spark Arrester A WARNING Failure to heed the following warnings while servicing the spark arrester 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 arrester while the system is hot Allow components to cool sufficiently before proceeding U
75. heels 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 29 FEATURES AND CONTROLS Auxiliary Foot Brake A WARNING Never back down a hill Applying the auxiliary brake when backing down a hill may cause rear tipover which could result in serious injury or death Use caution when applying the auxiliary brake Do not aggressively apply the auxiliary brake when going forward The rear wheels may skid and slide sideways causing loss of control and serious injury or death The auxiliary brake system is intended to be used as a backup for the main brake system Should the main system fail use the auxiliary foot brake 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 ake Fluid Leve Brake Fluid Check the brake fluid level Reservoir frequently for the auxiliary brake system The reservoir is located under the access panel in the front compartment Maintain the fluid level between the maximum and minimum marks Use DOT 4 brake fluid only 30 FEATURES A
76. her reproductive harm Operate this vehicle only outdoors or in well ventilated areas Protective Apparel Riding in this vehicle without wearing an approved helmet and protective eyewear increases the risk of a serious injuries in the event of an accident Always wear an approved helmet that fits properly and eye protection goggles or face shield Using Alcohol or Drugs Operating the ATV after consuming alcohol or drugs could adversely affect operator judgment reaction time balance and perception Never consume alcohol or drugs before or while operating an ATV 11 SAFETV Safetv Warnings Carrving a Passenger Carrying a passenger greatly reduces the operator s ability to balance and control the ATV which may result in an accident or overturn Never carry a passenger on this ATV 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 oper
77. ill help the spooling of the winch cable and reduce the load on the fairlead D If freeing a stuck vehicle by attaching to a tree use an item such as a tow strap to avoid damaging the tree during winch operation Sharp cables and chains can damage and even kill trees Please remember to TreadLightly treadlightly org E Before operating the winch be sure that the safety latch on the winch cable hook is fully seated when the load is attached F Never operate your winch with a damaged hook or latch Always replace damaged parts before using the winch YES NO 69 WINCH GUIDE Winch Operation 5 6 Ta 10 70 Never remove the hook strap from the hook Release the winch clutch and pull out the winch cable Pulling out as much cable as possible maximizes the winch s pulling capacity Always be sure that at least five 5 full turns of winch cable are wrapped around the winch drum at all times The friction provided by this wrapped cable allows the drum to pull on the winch cable and move the load Read and follow the Shock Loading Winch Damping and Winch Rigging sections of this manual for details on safe winch use A In order to absorb energy that could be released by a winch cable failure always place a damper on the winch cable A damper can be a heavy jacket tarp or other soft dense object A damper can absorb much of the energy released if a winch cable breaks when winching Even a tree limb c
78. in operation 39 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Programmable Service Interval When the hours of engine operation equal the programmed service interval setting the wrench icon will flash for 5 seconds each time the engine is started When this feature is enabled it provides a convenient reminder to perform routine maintenance The service interval is programmed at 50 hours at the factorv Use the following procedure to change the service interval 1 Press the MODE button until remaining service hours display 2 Press and hold the MODE button 3 When the service hours flash press and release the MODE button to advance the hours to the desired setting including OFF Press and hold the MODE button to set the new service hour interval Diagnostic Display Mode The EFI diagnostic display mode is for informational purposes only Please see your POLARIS dealer for all major repairs The diagnostic mode is accessible only when the check engine warning indicator activates after the key has been turned on Leave the key on if you want to view the active code failure code The diagnostic mode becomes inaccessible if the key is turned off and on and the warning indicator is no longer active This allows the determination of persistent as well as intermittent faults Inactive codes are stored in the history of the unit 40 FEATURES AND CONTROLS Instrument Cluster
79. ing at an angle is unavoidable follow these precautions A Look at the winch drum occasionally Never let the winch cable stack or accumulate at one end of the winch drum Too much winch cable at one end of the winch drum can damage the winch and the winch cable B If stacking occurs stop winching Follow step 15 on page 72 to feed and rewind the cable evenly before continuing the winch operation 13 Never winch up or down at sharp angles This can destabilize the winching vehicle and possibly cause it to move without warning 14 Never attempt to winch loads that weigh more than the winch s rated capacity 15 The winch motor may become hot during winch use If you winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 16 Never touch push pull or straddle the winch cable while winching a load 17 Never let the winch cable run through your hands even if wearing heavy gloves ay 18 Never release the clutch on the winch A when the winch cable is under load 19 Never use the winch for lifting or transporting people 66 WINCH GUIDE Winch Safetv Precautions 20 21 22 23 24 25 Never use the winch to hoist or suspend a vertical load Never immerse or submerse your winch in water Take your winch to your dealer for service if this occurs Always inspect your winch and winch c
80. is prohibited for anyone under 16 years of age 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 an ATV safely and could be susceptible to accident or injury 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 10 SAFETV Safetv Warnings Handling Gasoline Gasoline is highly flammable and explosive under certain conditions e Always exercise extreme caution whenever handling gasoline e Always refuel with the engine stopped and outdoors or in a well ventilated area e 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 e 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 ot
81. iss asa te siesta 96 98 Wheel Installation 98 Wheel Nut Torque 98 Wheel Removal 97 Toe Aligfiment ssusainanseznssses 94 Towing Capacities 64 Towing Loads 64 Trail Etiquette 5 000 50 Trainin erede se econ Ea 7 Transmission Gear Selector 25 Transmission Oil 86 Transporting the ATV 124 Turning Around on a Hill 58 Turning the Vehicle 53 V Vehicle Identification Numbers 6 Vehicle Immersion 108 WwW Warning Symbols 4 Washing the Vehicle 120 121 Wheel Hub Tightening 97 Wheel Installation 98 Wheel Nut Torque Specifications 98 Wheel Removal 97 Winch Cable Care 73 Winch Maintenance Service Safety 76 Winch Operation 68 72 Winch Safety Precautions 65 67 Winch Shock Loading 74 75 AWARNING Improper vehicle use can result in SEVERE INJURY or DEATH ALWAYS USE NEVER USE NEVERCARRY NEVER USE AN APPROVED ON PUBLIC PASSENGERS WITH DRUGS HELMET AND ROADS OR ALCOHOL PROTECTIVE GEAR NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control
82. k displays time in a 12 hour or 24 hour format If the engine is turned off press the MODE button The time will display for 5 10 seconds See page 39 for resetting instructions Service Reminder Display A flashing wrench symbol alerts the operator that the preset service interval has been reached The vehicle should be brought to your dealer for scheduled maintenance See page 39 for resetting instructions 4X4 Display This icon displays when the 4X4 system is engaged switch is on either ADC 4X4 or 4X4 37 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center The reverse override button acts as the MODE button when pressed and released quickly The transmission cannot be in reverse when using the override button as a MODE button This feature does not contain a vehicle speed lockout function and can be used at any operating speed Display Units Standard Metric The display can be changed to display either standard or metric units of measurement Tip To exit the set up mode at any time wait 10 seconds The display automatically exits and returns to the odometer display Standard Display Metric Display Distance Miles Kilometers Time 12 Hour Clock 24 Hour Clock 1 Turn the key to the OFF position 2 Place the transmission in neutral 3 Press and hold the MODE button while turning the key to the ON position 4 When the display flashes the distance setting
83. k operation a Brake light tail lamp Check operation 105 Riding gear Wear approved helmet goggles and 8 protective clothing 48 OPERATION Safe Operation Practices 1 2 10 11 12 13 14 Complete the recommended safetv training before operating this vehicle See page 7 Do not allow anvone under 16 vears of age to operate this vehicle Do not allow anvone with cognitive or phvsical disabilities to operate this vehicle Never carrv a passenger on this ATV Engine exhaust fumes are poisonous Never start the engine or let it run in an enclosed area Before operating learn how to use the auxiliarv brake for emergency situations if service brakes become inoperable 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 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 Drive in a manner appropriate for your 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 Never consume alcohol or drugs before or while operating an ATV Always use the size and type of tires specified for your vehicle Always maintain proper
84. l help keep vour vehicle in safe reliable condition Inspect clean lubricate adjust and replace parts as necessarv When inspection reveals the need for replacement parts use genuine POLARIS parts available from vour POLARIS dealer Record maintenance and service in the Maintenance Log beginning on page 141 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 e Frequent immersion in mud water or sand e Racing or race style high RPM use e Prolonged low speed heavy load operation e Extended idle e Short trip cold weather operation Pay special attention to the oil level A rise in oil level during cold weather can indicate contaminants collecting in the oil sump or crankcase Change oil immediately if the oil level begins to rise Monitor the oil level and if it continues to rise discontinue use and determine the cause or see your dealer 78 MAINTENANCE Periodic Maintenance Chart Maintenance Chart Kev Svmbol Description gt Perform these operations more often for vehicles subjected to severe use E Emission related servic
85. llow a greater distance for braking e NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg e NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 lbs 91 kg and or front cargo loads are above 100 Ibs 45 kg Always follow the instructions in the owner s manual for carrying cargo or pulling a trailer See pages 62 63 Operating on Frozen Bodies of Water Operating on frozen bodies of water may result in serious injury or death if the ATV and or the operator fall through the ice Never operate the ATV on a frozen body of water unless you have independently verified that the ice is sufficiently thick to support the weight and moving force of the ATV you and your cargo together with any other vehicles in your party Variances in snow depth and or water currents may result in uneven ice thickness Always check with local authorities and residents to confirm ice conditions and thickness over your entire route ATV operators assume all risk associated with ice conditions on frozen bodies of water Poor Visibility Operating the 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
86. mended fluid Use of other fluids may result in improper operation of components Maintain the fluid level at the bottom of the fill hole threads The fill plug is located on the right side of the demand drive unit The drain plug is located on the bottom right side of the unit Fluid Check 1 Position the vehicle on a level surface Remove the fill plug Check the fluid level 2 Add the recommended fluid as needed to bring the level to the bottom of the fill hole threads 3 Reinstall the fill plug Torque to specification Fluid Change Drain Plug 1 Position the vehicle on a level surface Remove the fill plug 2 Place a drain pan under the demand drive unit Remove the drain plug Allow the fluid to drain completely Clean and reinstall the drain plug Torque to specification Add the proper amount of the recommended fluid Reinstall the fill plug Torque to specification Oy ne A Check for leaks Dispose of used fluid properly 87 MAINTENANCE Rear Gearcase Oil See the table on page 82 for fluid recommendations capacities and plug torques Alwavs check and change the rear gearcase oil at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 See page 129 for the part numbers of POLARIS products The fill plug is located on the rear of the gearcase The drain plug is located on the bottom of the gearcase Maintain the fluid level at the bottom of the fill hole threads Do
87. ming See your dealer Mechanical failure See your dealer Loose ignition connections Check all connections and tighten Water present in fuel Replace with fresh recommended fuel Leaking exhaust components See your dealer 126 TROUBLESHOOTING Engine Pings or Knocks Poor qualitv or low octane fuel Replace with recommended fuel Incorrect ignition timing See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Engine Runs Irregularly Stalls or Misfires Fouled or defective spark plugs Inspect clean and or replace spark plugs Worn or defective spark plug wires See vour dealer Incorrect spark plug gap or heat range Set gap to specs or replace plugs Loose ignition connections Check all connections and tighten Water present in fuel Replace with new fuel Low batterv voltage Recharge batterv to 12 8 VDC Kinked or plugged fuel tank vent line Inspect and replace Incorrect fuel Replace with recommended fuel Clogged air filter Inspect and clean or replace Reverse speed limiter malfunction See vour dealer Electronic throttle control malfunction See vour dealer Other mechanical failure See vour dealer Possible Lean Fuel Cause Solution Low or contaminated fuel Add or change fuel clean the fuel svstem Kinked or plugged fuel tank vent line Inspect and replace Low octane fuel Replace with recommende
88. n center is located in the instrument cluster All segments will light up for one second at start up If the instrument cluster fails to illuminate a battery over voltage may have occurred and the instrument cluster may have shut off to protect the electronic speedometer If this occurs take the ATV to your POLARIS dealer for proper diagnosis The information center is set to display standard units of measurement and a 12 hour clock at the factory To change to metric and or a 24 hour clock see page 39 sss IW Trip CRP MA IWIN WANNA INA IAN Via aria YANN UN 36 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center 1 Tip Gear Display This area displays gear shifter position H High Gear L Low Gear N Neutral R Reverse Gear P Park Gear Signal Error or shifter between gears Fuel Gauge Display The segments of the fuel gauge show the level of fuel in the fuel tank When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer Information Display This area displays odometer trip meter engine hour meter engine speed and programmable service hour interval Active Descent Control Display This icon displays when ADC is active See page 33 Clock Display The cloc
89. n them 5 Lower the vehicle to the ground 6 Torque the wheel nuts to specification WARNING Loose nuts could cause a tire to come off during operation which could result in an accident or overturn Always ensure that all nuts are torqued to specification Wheel Nut Torque Specifications Check the wheel nut torques occasionally and when they ve been loosened for maintenance service Wheel Type Nut Torque All 75 ft lbs 102 Nm 98 MAINTENANCE Air Filter 1 Remove the seat 2 Remove the air box cover strap and remove the air box cover 3 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 Pre Filter main filter if needed KA 6 Reinstall the filter into the air Main X box A 7 Reinstall the air box cover O L and the seat amp 99 MAINTENANCE Fuse Replacement If the engine stops or will not start or if vou experience other electrical failures a fuse mav need replacement Locate and correct anv short circuits that mav have caused the blown fuse then replace the fuse Spare fuses are provided in the fuse box 1 Remove the front rack 2 Remove the fuse box cover 3 Remove the suspect fuse from the fuse panel If the fuse is blown install a new fuse with the same amperage rating 4 Reinstall the fuse box cover 5
90. nal or graphic label becomes illegible or comes off contact your POLARIS dealer to purchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label General Warning WARNING Improper ATV use can result in SEVERE INJURY or DEATH ALWAYS USE AN APPROVED HELMET AND PROTECTIVE GEAR NEVER USE ON PUBLIC ROADS NEVER CARRY PASSENGERS NEVER USE WITH DRUGS OR ALCOHOL NEVER operate e without proper training or instruction e at speeds too fast for your skills or the conditions e on public roads a collision can occur with another vehicle e with a passenger passengers affect balance and steering and increase risk of losing control ALWAYS use proper riding techniques to avoid vehicle overturns on hills and rough terrain and in turns e avoid paved surfaces pavement may seriously affect handling and control LOCATE AND READ OWNER S MANUAL FOLLOW ALL INSTRUCTIONS AND WARNINGS 7175376 20 SAFETV Safetv Labels and Locations DAG General Warning Discretionary Warning Age 16 Warning Reverse Override Warning 4X4 Caution Discretionary Warning WARNING e Never operate this ATV on HILLS steeper than 25 degrees 25 To prevent overturn on hilly terrain use throttle and brakes gradually and shift weight uphill e REVERSE operation can be dangerous even at low speeds Steering becomes difficult To prevent loss of control avoid sudden braking or
91. ne speed above idle or while the vehicle is moving could cause transmission damage Whenever the ATV is left unattended always place the transmission in PARK and lock the parking brake Belt Life To extend belt life use low forward gear when pulling a heavy load at less than seven miles per hour for extended periods and when operating uphill at a slow speed YEZH 23 FEATURES AND CONTROLS Throttle Lever A 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 throttle release switch could result in failure to perform as designed which could result in an accident Do not attempt to modify the throttle release switch or replace it with any after market throttle mechanisms Always ensure that the throttle cable is installed and properly routed to the throttle release switch Engine speed and vehicle movement are controlled by pressing the throttle lever The throttle lever is spring loaded Engine speed returns to idle when the lever is relea
92. ng rolling backwards or improperly dismounting while climbing a hill could cause an overturn e Always maintain a steady speed when climbing a hill e Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 If all forward speed is lost Keep body weight uphill e Apply the brakes e Lock the parking brake when fully stopped e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 58 If the ATV begins rolling downhill e Keep body weight uphill e Never apply engine power e Never apply the rear brake while rolling backwards Apply the single lever brake gradually e When fully stopped apply the rear brake as well and then lock the parking brake e Dismount on uphill side or to either side if ATV is pointed straight uphill e Turn the ATV around and remount following the procedure described in the owner s manual See page 58 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 25 degrees 15 SAFETV Safetv Warnings Operating in Unfamiliar Terrain Failure to use extra caution when operating on unfamiliar terrain could result in an accident or overturn Unfamiliar terrain mav contain hidden r
93. ng 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 e Always follow all recommended maintenance procedures Always look for and remove debris inside and around the clutch and vent system when replacing the belt e See your dealer as outlined in the owner s manual e This PVT system is intended for use on POLARIS products only Do not install it in any other product e Always make sure the PVT housing is securely in place during operation 110 MAINTENANCE PVT Svstem 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 centrifugal 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 1600 1800 RPM However in high range at 3 MPH 5 km
94. ng to all four wheels when the vehicle descends a hill or incline Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill Engaging Active Descent Control The ADC system will automatically engage when all four of the following conditions occur e The 4X4 switch must be in the ADC 4X4 position e Vehicle speed must be 15 mph 25 km h or less e The throttle must be closed throttle lever released e The transmission must be in gear high low or reverse Disengaging Active Descent Control The ADC system will automatically disengage if at least one of the following conditions occur e The 4X4 switch is moved out of the ADC 4X4 position e Vehicle speed exceeds 15 mph 25 km h e The throttle is open throttle is applied e The transmission is shifted to neutral or park 33 FEATURES AND CONTROLS Instrument Cluster NOTICE High water pressure mav damage ATV components Wash the ATV bv 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 spravs to contact the lens Immediatelv clean off anv gasoline that splashes on the instrument cluster Digital Analog Gauge Speedometer The speedometer displavs vehicle speed in either miles per hour MPH or kilometers per hour km h Indicator Lamps Speedometer
95. ngth of string between two stands as shown in the illustration Position the stands so l that the string is flush with the side of the rear I tire If available you may use a long straight edge instead of string 2 l 4 Measure the distance from the string to the ANS E rim at the front 1 and O rear 2 of the front rim The rear measurement should be 1 8 1 4 inch 3 6 mm more than the front measurement on each side of the vehicle to obtain the recommended 1 4 1 2 inch 6 12 mm toe out alignment 5 Repeat the measurement procedure on the other side of the vehicle 6 Ifyou discover improper alignment see your POLARIS dealer for service 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 94 MAINTENANCE Seat Removal l 1 Grasp one side of the seat near the rear edge 2 Pull upward abruptly to disengage the under seat fasteners 3 Remove the seat Side Panel Footwell Removal Remove the seat before removing a side panel To remove a side panel or footwell remove the fasteners securing it to the frame Lift the right side panel upward while removing it to clear the shifter knob Plastic Rivet Torx Head Screw Plastic Rivet Vi Hex Head Screw 95 MAINTENANCE Tires A WARNING Operating your ATV with worn tire
96. not overfill Oil Check 1 Position the vehicle ona level surface 2 Remove the fill plug Check the oil level 3 Add the recommended oil as needed to bring the level to the bottom of the fill hole threads Do not overfill 4 Reinstall the fill plug Torque to specification 88 MAINTENANCE Rear Gearcase Oil Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain hole 3 Remove the drain plug Allow the oil to drain completely 4 Clean and reinstall the drain plug with a new sealing washer Torque to specification 5 Remove the fill plug Add the proper amount of the recommended oil Do not overfill 6 Reinstall the fill plug Torque to specification Check for leaks 8 Dispose of used oil properly 89 MAINTENANCE Power Steering Unit If your model is equipped with power steering frequently Clean clean the areas around and on Often the power steering unit to allow proper cooling Clean these areas thoroughly 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 Cooling System The engine coolant level is controlled by the recovery system Recovery system components are the recovery bottle the radiator filler neck the radiator pressure cap and the connecting hose As coolant operating temperat
97. nsibility or by acts of God Any qualified repair shop or person may maintain replace or repair the emission control devices or systems on your vehicle POLARIS recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle POLARIS also recommends that you use only POLARIS parts It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle s emission controls Tampering with emission controls is prohibited by federal law California Residents Certain POLARIS Off Road Vehicles are available in 49 state and 50 state versions Only the 50 state models are certified for sale in California The 50 state models available for sale in California are identified by the letter C in the model name e g R13UH88A_C The POLARIS 50 state models are designed and built with features such as a reduced cargo box capacity Any modifications to these features may be a violation of the applicable California regulations and may void this limited emissions warranty offered by the manufacturer If you have any questions regarding your warranty rights and responsibilities please contact POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 140 MAINTENANCE LOG Present this section of vour manual to vour dealer each time vour vehicle is serviced This will p
98. nstrument Cluster Diagnostic Displav Code Definitions Diagnostic Codes Component Condition SPN FMI EPS Models Only Vehicle Speed Sensor Data Valid But Above Normal 84 0 Operational Range Most Severe Level Data Erratic Intermittent Or 84 2 Incorrect Abnormal Rate Of Change 84 10 Received Network Data In Error 84 19 System Power Data Valid But Above Normal 168 0 Operational Range Most Severe Level Voltage Above Normal Or 168 3 Shorted To High Source Voltage Below Normal Or 168 4 Shorted To Low Source Engine Speed Data Valid But Above Normal 190 0 Operational Range Most Severe Level Data Erratic Intermittent Or 190 2 Incorrect Received Network Data In Error 190 19 ECU Memory Bad Intelligent Device Or 628 12 Component Out Of Calibration 628 13 Calibration Out Of Calibration 630 13 Steering Over Current Shut Down Current Above Normal Or 520221 6 Grounded Circuit Steering Excessive Current Error Current Above Normal Or 520222 6 Grounded Circuit Steering Torque Partial Failure Condition Exists 520223 31 Steering Torque Full Failure Condition Exists 520224 31 44 FEATURES AND CONTROLS Instrument Cluster Diagnostic Displav Code Definitions Diagnostic Codes Component Condition SPN FMI EPS Models Only EPAS Inverter Temperature Data Valid But Above Normal 520225 0 Operational Range Most Se
99. ny 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 SAFETV Safetv Warnings A 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
100. ocks bumps or holes that could cause loss of control or overturn Travel slowly and use extra caution when operating on unfamiliar terrain Alwavs be alert to changing terrain conditions Operating on Slipperv Terrain Failure to use extra caution when operating on excessivelv rough slipperv or loose terrain could cause loss of traction loss of control accident or overturn Do not operate on excessivelv rough slipperv or loose terrain Alwavs use extra caution on rough slipperv or loose terrain Operating Improperly in Reverse Improperly operating in reverse could result in a collision with an obstacle or person Always follow proper operating procedures as outlined in this manual See page 61 Before shifting into reverse gear always check for obstacles or people behind the ATV When it s safe to proceed back slowly 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 16 SAFETV Safetv Warnings 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
101. on the winch Slowly winch in the slack in the winch cable Select the proper vehicle gear to propel the stuck vehicle in the direction of winching Shift to the lowest gear available on the stuck vehicle Slowly and carefully apply vehicle throttle and winch together to free the vehicle Stop winching as soon as the stuck vehicle is able to propel itself without the help of the winch Detach the winch cable hook Rewind the winch cable evenly back onto the winch drum following the instructions in this manual Never attempt to winch another stuck vehicle by attaching the winch cable to a suspension component brush guard bumper or cargo rack Vehicle damage may result Instead attach the winch to a strong portion of the vehicle frame or hitch 71 WINCH GUIDE Winch Operation 13 Extensive winching will run down the batterv on the winching vehicle Let the winching vehicle s engine run while operating the winch to prevent the batterv from running low if winching for long periods 14 The winch motor mav become hot during winch use If vou winch for more than 45 seconds or if the winch stalls during operation stop winching and permit the winch to cool down for 10 minutes before using it again 15 After winching is complete especiallv if winching at an angle it may be necessary to re distribute the winch cable across the winch drum You will need an assistant to perform this task Release the clutch on the winch Fee
102. r greater emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 500 hours of engine operation 5000 kilometers 3100 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first The warranty period for ATVs less than 100cc emissions certified vehicles starts on the date of purchase by original retail purchaser and continues for a period of 250 hours of engine operation 2500 kilometers 1550 miles of vehicle travel or 30 calendar months from the date of purchase whichever comes first This EPA emissions warranty period is extended for at least as long as the standard factory warranty that Polaris provides on the vehicle as a whole The EPA emissions warranty period does not further extend if you purchase additional warranty coverage in the form of a service contract or other paid warranty extension but emission related parts may be covered subject to the terms of any such paid service contract or paid warranty extension This emissions limited warranty covers components whose failure increases the vehicle s regulated emissions and it covers components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaus
103. rent before entering water 2 Choose a crossing where both banks have gradual inclines Maximum Depth 3 Avoid operating through deep or fast flowing water NOTICE Major engine damage can result if the vehicle is not thoroughly inspected after operation in water Perform the services outlined in the maintenance chart See page 79 The following areas need special attention engine oil transmission oil demand drive fluid rear gearcase oil and all grease fittings If the vehicle tips or overturns in water or if the engine stops during or after operating in water restarting can result in serious engine damage Transport the vehicle to your dealer for service before restarting the engine If this is not possible follow the vehicle immersion inspection and drying procedures outlined on page 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 e Proceed slowly Avoid rocks and obstacles e Balance your weight carefully Avoid sudden movements e Maintain a steady rate of speed Do not make sudden turns or stops Do not make sudden throttle changes 59 OPERATION Driving Over Obstacles Follow these precautions when operating over obstacles 2 60 Always check for obstacles before operating in a new are
104. ring a helmet can prevent a severe head injurv Whenever riding a POLARIS vehicle alwavs wear a helmet that meets or exceeds estab lished safetv standards Approved helmets in the USA and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed bv the distinguishing number of the countrv which has 051039 granted approval The approval number and serial 0006 31 number will also be displaved on the label SAFETV Safe Riding Gear Eve Protection Do not depend on eveglasses or sunglasses for eve protection When ever riding a POLARIS vehicle alwavs 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 eve wear is kept clean Gloves Off road stvle gloves with knuckle pads are the best for comfort and protection Boots The best footwear is a pair of sturdv over the calf boots with low heels Clothing Alwavs wear long sleeves and long pants to protect arms and legs Rid ing pants with kneepads and a jersev with shoulder pads provide the best protection Equipment Modifications We stronglv recommend that consumers do not install on a POLARIS ATV any equipment that may increase the speed or power of the vehicle or make a
105. rocedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Products registered to government officials or military personnel on assignment outside of the country where the product was purchased will continue to be covered by the Limited Warranty 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 or in different countries If any of the above terms are void because of federal state local law all other warranty terms will remain in effect For questions call POLARIS Customer Assistance United States amp Canada 1 800 POLARIS 1 800 765 2747 French 1 800 268 6334 137 WARRANTV U S A EPA Emissions Limited Warrantv This emissions limited warrantv is in addition to the POLARIS standard limited warrantv for vour vehicle POLARIS Industries Inc warrants that at the time it is first purchased this emissions certified vehicle is designed built and equipped so it conforms with applicable U S Environmental Protection Agencv emission regulations POLARIS warrants that the vehicle is free from defects in materials and workmanship that would cause it to fail to meet these regulations The warranty period for off road vehicles 100cc o
106. rovide vou and future owners with an accurate log of maintenance and ser vices performed DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 141 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 142 MAINTENANCE LOG DATE MILES KM OR HOURS TECHNICIAN SERVICE PERFORMED COMMENTS 143 INDEX 0 9 4X4 Switch 0 24 32 A Access Front Compartment 46 Accessories 124 Active Descent Control System 33 ADC Syst m Li isti iiei 33 AIr PIET cis peana i Miso 99 All Wheel Drive System 32 33 Auxiliary Foot Brake 93 B Battery Charging ia nonsenss 118 119 Extreme Use sbekissensanzj 31 Installation 117 Removal ccc eee keen 116 LOLA LE sisa opi leecabie seca 117 Belt Life isc5 sena whsanedases 25 BOOS s l ksivi en eds eds ne el 9 Brake Fluid Auxiliary Foot Brake 30 Brake Fluid Main Brake System 28 Brake Lever 0 si sence smes Zi Brake Foot 30 93 Brake Hand Lever 93 Brake Parking 6 s3sascaciweses 29 Brakelight 0 204 004 ne vise 105 Brakes g i sa 93 Break In Period 47 Cc Camber Adjustment 113 Cargo wa bebe
107. s 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 129 for recommended tire type size and pressure Tire Tread Depth Always replace tires 1 8 3 mm Z when tread depth is worn to 1 8 3 mm or less p AS 96 MAINTENANCE Tires Front Wheel Hub Tightening Front wheel bearing tightness and spindle nut retention are critical component operations All service must be performed by your authorized POLARIS dealer Wheel Removal 1 Stop the engine 2 Place the transmission in PARK 3 Lock the parking brake 4 Loosen the wheel nuts slightly WARNING Do not service axle nuts that have a cotter pin installed See your POLARIS dealer 5 Elevate the side of the vehicle by placing a suitable stand under the footrest frame 6 Remove the wheel nuts 7 Remove the wheel 97 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 if equipped 4 Install the wheel nuts and finger tighte
108. s and Locations Rack Rack Warning Warning Clutch Cover Warning Hitch Capacit under seat Label Clutch Cover Warning WARNING e Moving parts hazard under belt clutch guard To prevent serious injury do not operate vehicle with guard removed e 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 7175488 Rack Warning Front and Rear WARNING e 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 e Max Rack Loads Front 120 lbs 54 kg Rear 240 Ibs 109 kg 7175448 Hitch Capacity Label TRAILER MAX WEIGHT 1500 LBS 682 KG ON LEVEL GROUND 850 LBS 386 KG UP TO 15 GRADE HITCH MAX VERTICAL WEIGHT 150 LBS 68 KG 7170509 23 FEATURES AND CONTROLS Switches Headlight Mode Reverse Override Button g Main Kev Stop Switch Switch Mode Reverse Override Switch This vehicle is equipped with a reverse speed limiter system To gain additional wheel speed while backing release the throttle and depress the override button WARNING Pressing the override button while the throttle is open can cause loss of control which may result in serious injury or death Always release the throttle before pressing the override button The reverse override button also acts as a MODE button when held down for approximately one half
109. s 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 bv the amount of tongue weight e The combination of rear rack cargo weight and tongue weight must not exceed the rear rack capacity e The total load operator accessories cargo and weight on hitch must not exceed the maximum weight capacity of the vehicle NOTICE Using an improper hitch or exceeding Maximum the maximum tongue weight capacity 4 10 cm 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 850 XP 1000 Maximum Towed Load Level Ground 1500 Ibs 680 kg 1500 Ibs 680 kg Maximum Vertical Hitch Weight 150 Ibs 68 kg 150 Ibs 68 kg 64 WINCH GUIDE These safety warnings and instructions apply if your vehicle came equipped with a winch or if you choose to add an accessory winch to your vehicle A WARNING Improper winch use can result in SEVERE INJURY or DEATH Always follow all winch instructions and warnings in this manual Your winch may have a cable made of either wire rope or specially designed synthetic rop
110. sconnect the red positive battery cable last Disconnect the battery hold down strap Lift the battery out of the ATV Pb E 116 MAINTENANCE Batterv Batterv Installation Using a new batterv that has not been fullv charged can damage the batterv and result in a shorter life It can also hinder vehicle performance Follow the batterv charging instructions on page 118 before installing the batterv An optional extreme use batterv mav be available for vour model If the performance of the factorv installed battery is inadequate due to operation in extreme cold or due to extended use of multiple electrical accessories please see vour POLARIS dealer Ask vour dealer to provide anv installation procedures that mav differ for an extreme use batterv 1 Ensure that the battery is fully charged Place the battery in the battery holder Coat the terminals with dielectric grease or petroleum jelly Secure the battery hold down strap Connect and tighten the red positive cable first Connect and tighten the black negative cable last SO Or ee Verify that cables are properly routed Cables should be safely tucked away at the front and rear of the battery 8 Install the front rack 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
111. se and pull the harness assemblv awav from the headlight assembly 2 Remove the headlamp and install the new headlamp 3 Reinstall the harness assembly into the headlight assembly 4 Turn the headlight harness clockwise to secure the head lamp Taillight Brakelight Lamp Replacement 1 Remove the harness connector from the back of the light assembly 2 Turn the lamp counter clockwise to remove it 3 Install the new lamp Taillight 4 Reinstall the harness connector 5 Test the light for proper operation 105 MAINTENANCE Spark Plugs Spark Plug Recommendations Refer to the specifications section beginning on page 129 for the recommended spark plug tvpe and gap for vour vehicle Torque spark plugs to specification NOTICE Using non recommended spark plugs can result in serious engine damage Alwavs use POLARIS recommended spark plugs Plug Condition Torque Specification New Spark Plug 18 20 ft Ibs 24 27 Nm Previousiv Installed 18 20 ft Ibs Spark Plug 24 27 Nm 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 Immediatelv check the spark plugs for correct color See page 107 CAUTIONI A hot exhaust svstem and engine can cause burns Wear protective gloves when removing a spark plug for inspection 1 Rotate th
112. se the following procedure to periodically purge accumulated carbon from the exhaust pipe muffler 1 Remove the arrester clean out plug from the bottom of the muffler 2 Place the transmission in PARK 3 Start the engine Quickly squeeze and release the throttle lever several times to purge L carbon from the system 5 If carbon comes out of the exhaust cover or plug the Clean Out Plug exhaust outlet s 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 Repeat steps 4 to 6 until no more particles are expelled 9 Stop the engine Allow the arrester to cool 10 Reinstall the arrester clean out plug and remove the exhaust outlet cover or plug 109 MAINTENANCE PVT Svstem A 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 testi
113. second See the instrument cluster information beginning on page 34 The transmission cannot be in reverse when using the override button as a MODE button 4X4 Switch Use the 4X4 switch to engage ADC 4X4 4X4 or 2X4 See page 33 The vehicle automatically engages 4X4 when operating in reverse if the switch is set to either 4X4 position 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 24 FEATURES AND CONTROLS Switches Engine Stop Switch lt gt Move the stop switch either ce left or right to the OFF position g to stop the engine quickly OCN Move the stop switch to the RUN position before OPF RUN ORF attempting to start the engine The engine will not start or run when the switch is off Both the main switch and the engine stop switch will shut off all electrical power to the vehicle including lights Main Key Switch Use the main key switch to start the engine See page 51 for starting pro cedures Automatic Transmission Gear Selector The transmission gear selector is located Gear on the right side of the vehicle Selector High Gear Low Gear Neutral Reverse 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 engi
114. sed This ATV is equipped with a throttle release switch which is designed to reduce the risk of a frozen or stuck throttle If the throttle cable should stick in an open position when the operator releases the throttle lever engine speed will be limited to idle speed 26 FEATURES AND CONTROLS Brake Lever A 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 27 FEATURES AND CONTROLS Master Cvlinder Brake Fluid A 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
115. sharp turns 7175511 Age 16 Warning WARNING Operating this ATV if you are under the age of 16 increases your chance of severe injury or death NEVER operate this ATV if you are under age 16 7175374 Reverse Override Warning 4X4 Caution WARNING Improper use of the 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 21 SAFETV Safetv Labels and Locations No Passenger Warning Tire Pressure Load Warning No Passenger Warning WARNING NEVER ride as a passenger avers can cause a loss of control resulting in SEVERE INJURY or 7175378 Tire Pressure Load Warning WARNING Improper tire pressure or overloading can cause loss of control Loss of control can result in severe injury or death e Cold tire pressure Front 7 0 psi 48 3 kPa Rear 7 0 psi 48 3 kPa e Maximum weight capacity 575 Ibs 261 kg e Lug nut torque values 75 ft lbs 102 Nm NEVER exceed 50 MPH 80 km h when rear cargo loads are above 75 lbs 34 kg and or front cargo loads are above 37 lbs 17 kg NEVER exceed 10 MPH 16 km h when rear cargo loads are above 200 Ibs 91 kg and or front cargo loads are above 100 Ibs 45 kg 7180603 22 SAFETV Safetv Label
116. skid 1 EILS lt gt Let O e y x CE NA Whenever riding on slipperv surfaces such as wet trails or loose gravel or during freezing weather follow these precautions 1 Do not operate on excessively rough slippery or loose terrain 2 Slow down when entering slippery areas 3 Engage 4X4 before wheels begin to lose traction NOTICE Severe damage to drive train may occur if the 4X4 is engaged while the wheels are spinning Allow the rear wheels to stop spinning before engaging 4X4 or engage 4X4 before wheels begin to lose traction 4 Maintain a high level of alertness reading the trail and avoiding quick sharp turns which can cause skids 5 Never apply the brakes during a skid Correct a skid by turning the handlebars in the direction of the skid and shifting your body weight forward 54 OPERATION Driving Uphill 25 Maximum Braking and handling are greatly affected when operating in hilly terrain Improper procedure could cause loss of control or overturn Whenever traveling uphill follow these precautions 1 FO S A A E ad 10 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 Drive straight uphill Avoid climbing steep hills 25 maximum Always check the terrain carefully before ascending any hill Never climb hills with excessively slippery or loose surfaces Keep both feet on the footrests Shift body weight uphill Proceed at a steady ra
117. smission 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 MAINTENANCE Camber and Caster The camber and caster are non adjustable Front and Rear Springs The front and rear shock absorber springs are adjusted by rotating the adjuster either clockwise or counter clockwise to increase or decrease spring tension Accessory springs for lighter and heavier riders are available through your POLARIS dealer Handlebars The handlebars can be adjusted for rider preference WARNING Improper adjustment of the handlebars or incorrect torquing of the adjuster block tightening bolts can cause limited steering or loosening of the handlebars resulting in loss of control and serious injury or death Follow the adjustment procedures exactly or see your POLARIS dealer for service 1 Remove the upper headlight pod 2 Loosen the four handlebar bolts 3 Adjust the handlebar to the desired height Be sure the handlebars do not contact the gas tank or any other part of the machine when turned fully to the left or right Handi bar 4 Torque the front two bolts to Bolts 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 113 MAINTENANCE Throttle Body Idle RPM Idle RPM is preset by the manufacturer If the engine idle sp
118. stick EE 83 MAINTENANCE Engine Oil Oil and Filter Change See the table on page 82 for fluid recommendations capacities and plug torques Always change the oil and filter at the intervals outlined in the Periodic Maintenance Chart beginning on page 79 Always change the oil filter whenever changing oil Oil Filter 1000 Top View Access l Drain Plug WE NN 850 Drain Plug 1 Position the vehicle on a level surface 2 Start the engine Allow it to warm up at idle for two to three minutes 3 Stop the engine 4 Clean the area around the drain plug 5 XP 1000 only Remove the three bolts securing the guard plate and remove the guard plate to access the oil filter 6 Place a drain pan under the crankcase 7 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 8 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 9 Reinstall the drain plug Torque to specification 84 MAINTENANCE Engine Oil Oil and Filter Change 10 11 12 13 14 15 16 17 18 19 20 21 22 23 Place shop towels beneath the oil filter Using an oil filter wrench available from vour POLARIS dealer turn the filter counter clockwise to remove it Using a clean drv cloth clean the
119. t emissions emission related components include any engine parts related to the following systems e Air induction system e Ignition system e Fuel system e Exhaust gas recirculation systems The following parts are also considered emission related components for exhaust emissions e Aftertreatment devices e Sensors e Crankcase ventilation valves e Electronic control units 138 WARRANTV U S A EPA Emissions Limited Warrantv The following parts are considered emission related components for evaporative emissions Fuel Tank Vacuum Control Diaphragms Fuel Cap Control Cables Fuel Line Control Linkages Fuel Line Fittings Purge Valves Clamps Vapor Hoses Pressure Relief Valves Control Valves Control Solenoids Electronic Controls As related to the evaporative emission control system Liquid Vapor Separator Carbon Canister Canister Mounting Brackets Carburetor Purge Port Connector o o o o e o o o o o o o 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 products THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT NEGLIGENCE
120. tap the MODE button to advance to the desired setting 5 Press and hold the MODE button to save the setting and advance to the next display option 6 Repeat the procedure to change remaining display settings 38 FEATURES AND CONTROLS Instrument Cluster Digital Analog Gauge Rider Information Center Clock Mode Tip The clock must be reset anv time the batterv has been disconnected or discharged 1 Turn the kev to the ON position Use the MODE button to toggle to the odometer displav 2 Press and hold the MODE button until the hour segment flashes Release the button 3 With the segment flashing tap the MODE button to advance to the desired setting 4 Press and hold the MODE button until the next segment flashes Release the button 5 Repeat steps 3 4 twice to set the 10 minute and 1 minute segments After completing the 1 minute segment step 4 will save the new settings and exit the clock mode 6 Turn the key to the OFF position Odometer Mode The odometer records and displays the distance traveled by the ATV Trip Meter Mode The trip meter records the distance traveled by the ATV if reset before each trip To reset select the trip meter mode Press and hold the MODE button until the meter resets to zero In the Rider Information Center the trip meter display contains a decimal point but the odometer displays without a decimal point Hour Meter Mode This mode logs the total hours the engine has been
121. te of speed and throttle opening Opening the throttle suddenly could cause the ATV to flip over backwards 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 Remain alert and be prepared to take emergency action This may include quick dismounting of the vehicle 55 OPERATION Driving on a Sidehill Sidehilling Driving on a sidehill is not recommended Improper procedure could cause loss of control or overturn Avoid crossing the side of any hill unless absolutely necessary If crossing a sidehill is unavoidable follow these precautions 1 2 3 4 56 Slow down Shift body weight uphill Keep your feet on the footrests If the vehicle begins to slide or tip quickly turn the front wheel downhill if possible or dismount on the uphill side immediately OPERATION Driving Downhill When driving downhill follow these precautions 1 Always move the 4X4 switch to ADC 4X4 before ascending or descending a hill See page 33 2 Avoid steep hills 25 maximum 3 Shift body weight uphill 4 Drive straight downhill 5 Slow down Excessive speed when traveling downhill can cause loss of control 6 Squeeze the brake lever gradually Applying the brakes too firmly may cause the rear wheels to lock which could result in loss of control Parking on an Incline Avoid parking on an incline if possible I
122. tions 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 122 MAINTENANCE Cleaning and Storage Storage Tips Fog the Engine 1 After stabilizing the fuel remove the spark plugs and add 2 3 tablespoons of engine oil To access the plug holes use a section of clear 1 4 hose and a small plastic squeeze bottle filled with the pre measured amount of oil 2 Reinstall the spark plugs Torque to specification 3 Apply dielectric grease to the inside of each spark plug cap and reinstall the caps onto the plugs 4 Turn the engine over several times using electric start Oil will be forced in and around the piston rings and ring lands coating the cylinder with a protective film of fresh oil 5 If POLARIS fuel system additive is not used the fuel tank fuel lines and injectors should be completely drained of gasoline Air Filter Air Box 1 Inspect and clean or replace the pre cleaner and air filter See page 99 2 Clean the air box Inspect and Lubricate Inspect all cables and lubricate all areas of the vehicle as recommended in the Periodic Maintenance Chart beginning on page 79 Battery Maintenance Remove the battery and recharge it as outlined on page 118
123. ttings 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 e Avoid the use of automotive products some of which can scratch the finish of your vehicle e 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 121 MAINTENANCE Cleaning and Storage Storage Tips NOTICE Starting the engine during the storage period will disturb the protective film created bv fogging and damage could occur Never start the engine during the storage period Clean the Exterior Make anv necessarv repairs and then clean the vehicle as recommended See page 120 Oil and Filter Change the oil and filter See page 84 Fluid Levels Inspect the following fluid levels Change fluids as recommended in the Periodic Maintenance Chart beginning on page 79 e Demand drive unit front gearcase e Rear gearcase e Transmission e Brake fluid change every two years and any time the fluid looks dark or contaminated e Coolant test strength Stabilize the Fuel 1 Fill the fuel tank 2 Add POLARIS Carbon Clean Fuel Treatment or POLARIS Fuel Stabilizer Follow the instruc
124. ure increases the expanding heated excess coolant is forced out of the engine past the pressure cap and into the recovery bottle As engine coolant temperature decreases the contracting cooled coolant is drawn back up from the bottle past the pressure cap and into the radiator Some coolant level drop on new vehicles is normal as the system is purging itself of trapped air Check the coolant level and maintain as recommended by adding coolant to the recovery bottle POLARIS recommends the use of POLARIS Antifreeze 50 50 Premix This antifreeze is already premixed and ready to use Do not dilute with water See page 129 for the part numbers of POLARIS products 90 MAINTENANCE Cooling Svstem Recoverv Bottle Coolant The recoverv bottle fluid level can be viewed from inside the front right wheel well Access the recovery bottle cap under the front storage compartment 1 View the fluid level in the bottle 2 Ifthe level is low remove the front rack 3 Remove the bottle cap and add coolant as needed Maintain the coolant level between the minimum and maximum marks on the bottle when the fluid is cool 4 Reinstall the cap 5 Reinstall the front rack Maximum Mark Minimum Mark Recovery Bottle Cap 91 MAINTENANCE Cooling Svstem Radiator Coolant To ensure that the coolant maintains its abilitv to protect the engine we recommend that the system be completely drained every five 5 years and fresh
125. use low range more frequently 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 ment Use the throttle quickly and effectively 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 or snow ingestion into the PVT system Dry out the PVT See page 112 Inspect clutch seals for damage if repeated leaking occurs 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
126. vere Level Data Valid But Above Normal 520225 16 Operating Range Moderately Severe Level EPAS Communications Receive Data Erratic Intermittent Or 520226 2 Data Error Incorrect Condition Exists 520226 31 Position Encoder Error Root Cause Not Known 520228 11 Bad Intelligent Device Or 520228 12 Component Condition Exists 520228 31 EPAS Software Error Bad Intelligent Device Or 520229 12 Component Condition Exists 520229 31 EPAS Power Save Condition Condition Exists 520231 31 EPS SEPIC Voltage Error Voltage Above Normal Or 524086 3 Shorted To High Source Voltage Below Normal Or 524086 4 Shorted To Low Source 45 FEATURES AND CONTROLS Front Rack Compartment Release the front rack latches Latches and remove the rack to gain access to the front compartment To reinstall the rack hold the rack as shown in the illustration Position the front edge in the tabs then push the rack downward and secure the latches raw z Access the following components in the front compartment e Radiator cap e Auxiliary foot brake fluid reservoir under access panel e Battery e Coolant recovery bottle cap e Electrical fuse relay components Brake Fluid Reservoir auxiliary Banery foot brake Coolant Bottle Cap Radiator Cap Electrical Fuse Relay 46 OPERATION Failure to operate the ATV properlv can result in a collision loss of control accident or overturn which may result in s

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